Reel editor for pre-print paper, sheet, and box manufacturing systems

ABSTRACT

Systems for providing efficient manufacturing of paper, sheet, and/or box products of varying size and structure, often with pre-applied print (“pre-print”), are provided herein. Efficient customer ordering/tracking, job aggregation, print imposition, corrugator planning, and tracking and adjustments throughout the manufacturing process are contemplated. A reel editor is configured to edit the roll based on waste and/or errors that occurred during various manufacturing processes (e.g., during printing). A control plan defining what is on each roll of printed web product may be updated after editing. Depending on the configuration, the reel editor may be integrated with various manufacturing components. The reel editor may be configured to determine if there is enough waste on the roll to even making editing worthwhile, such as based on desired quality of the images, customer requirements, different price points, among other possible factors.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/597,016, entitled “Reel Editor for Pre-Print Paper, Sheet, andBox Manufacturing Systems”, filed Dec. 11, 2017; U.S. Provisional PatentApplication No. 62/583,857, entitled “Reel Editor for Pre-Print Paper,Sheet, and Box Manufacturing Systems”, filed Nov. 9, 2017; and U.S.Provisional Patent Application No. 62/532,483, entitled “DigitalPre-Print Paper, Sheet, and Box Manufacturing Systems”, filed Jul. 14,2017, each of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

Example embodiments of the present invention generally relate to paper,sheet and box manufacturing systems and, more particularly, to reeleditors for pre-print paper, sheet and box manufacturing systems.

BACKGROUND

Paper, sheet, and/or box manufacturing systems may often include printsystems that print one or more images (e.g., symbols, marketing indicia,product information, etc.) on the product. For example, a roll of webproduct may pass through a printing press and receive one or moreimages. Such printing may occur after formation/processing of theproduct (e.g., a layered corrugate), often being called “post-print”.Alternatively, such printing may occur prior to formation of the product(e.g., on a top layer prior to formation of the finished product), oftenbeing called “pre-print”.

A reel map or control plan for the roll of web product may help definethe desired specifications/images for the finished product, such as inaccordance with one or more orders. Depending on the design of the reelmap, there may be waste within the roll. Further, the printing press mayproduce one or more images of poor quality. It may be desirable toremove such waste or poor images at various points throughout themanufacturing process. In this regard, unnecessary waste can be removedand more efficient manufacturing of the finished product may occur.

BRIEF SUMMARY

Embodiments of the present invention provide systems for providingediting of printed web product, such as in conjunction with paper,sheet, and/or box manufacturing systems. While some of the descriptionherein of example embodiments focuses on corrugated box manufacturing,some embodiments of the present invention are contemplated for extensioninto other product manufacturing, including other paper based productmanufacturing, such as folded carton, beverage, labels, flexible paper,industrial bags, plates, cups, décor, and many others.

Some embodiments of the present invention contemplate a designedplatform with various modules that can be used throughout themanufacturing process. For example, such modules/controllers can be usedto aggregate orders and information to prepare one or more reel maps(e.g., reel plans) for processing a roll of web product through themanufacturing process. The reel map may include information regardingone or more orders on the particular roll of web product. For example,the reel map may help define the one or more images printed on the webproduct. The one or more images may then be checked for defects and theroll may be edited, such as to remove excess waste on the roll and/orpoor images on the roll. In some embodiments, a reel editor may be usedto perform the roll editing. Further, the reel map may be updated toaccount for the removed or changed portion of the roll of web product.

In some embodiments, the reel editor may be configured to determine ifthere is enough waste on the roll of web product to even making editingworthwhile, such as based on cost of removing the waste, cost ofproceeding without removing the waste, desired quality of the images,customer requirements, different price points, among other possiblefactors.

In an example embodiment, a system for editing a roll of printed webproduct is provided. The system comprises a first winding stationcomprising a winding device that is configured to wind and unwind theroll of printed web product. The first winding station is configured toreceive the roll of printed web product. The system further comprises acutting station configured to enable one or more portions of the roll ofprinted web product to be removed. The system further comprises a secondwinding station that is configured to receive a tail end of the roll ofprinted web product and enable winding and unwinding of the roll ofprinted web product. The system further comprises a reel editor moduleconfigured to receive a control plan associated with the roll of printedweb product. Each roll of printed web product is associated with aroll-specific control plan. The control plan comprises roll data thatincludes data corresponding to one or more printed orders on the roll ofprinted web product. The roll data comprises waste data that includesone or more locations of waste sections on the roll of printed webproduct. Each of the waste sections corresponds to at least one of wasteon the roll of printed web product or unsatisfactory images that areprinted on the roll of printed web product. The reel editor module isconfigured to control the first winding device to unwind the roll ofprinted web product to position a location of a waste section of theroll of printed web product at the cutting station for removal of thewaste section to form an edited roll of printed web product. The reeleditor module is configured to control at least one of the first windingdevice of the first winding station or a second winding device of thesecond winding station to wind the edited roll of printed web productafter removal of the waste section. The reel editor module is configuredto update the control plan associated with the roll of printed webproduct by updating the roll data based on the removed waste sections toform an updated control plan associated with the edited roll of printedweb product.

In some embodiments, the reel editor module is further configured tocontrol at least one of the first winding device or the second windingdevice to unwind the edited roll of printed web product at the secondwinding station and rewind the edited roll of printed web product at thefirst winding station to form an updated roll of printed web productthat is rewound with a leading tail end on the outside circumference ofthe roll of printed web product.

In some embodiments, the reel editor module is configured to pull thecontrol plan from a vision system module.

In some embodiments, the reel editor module is configured to provide theupdated control plan to a corrugator control module for corrugation ofthe edited roll of printed web product.

In some embodiments, the reel editor module is configured to cause oneor more labels to be printed, wherein the one or more labels includeidentification of the edited roll of printed web product.

In some embodiments, the roll data comprises a length of printed webproduct associated with an order section on the roll of printed webproduct, wherein each order section comprises at least one structureoutline and at least one corresponding printed image within the at leastone structure outline. Further, the reel editor module is configured toupdate the control plan by updating, in an instance in which a portionof an order section was removed, the roll data with an updated length ofprinted web product associated with the order section.

In some embodiments, the roll data comprises a number of box outlinesassociated with an order section on the roll of printed web product,wherein each order section comprises at least one structure outline andat least one corresponding printed image within the at least onestructure outline. Further, the reel editor module is configured toupdate the control plan by updating, in an instance in which a portionof an order section was removed, the roll data with an updated remainingnumber of structure outlines associated with the order section on theedited roll of printed web product.

In some embodiments, the roll data comprises an overall length ofprinted web product on the roll of printed web product. The reel editormodule is configured to update the control plan by updating the rolldata with an updated overall length of printed web product based on anoverall length of web product that was removed.

In some embodiments, the cutting station comprises a slitting sectionconfigured to enable slitting the roll of printed web product into oneor more narrower rolls. In some embodiments, the roll of printed webproduct is slit into one or more narrower rolls based on one or morelanes that are indicated in the control plan. In some embodiments, thereel editor module is configured to update the control plan bygenerating a control plan for each of the one or more narrower rolls.

In some embodiments, the system further comprises one or more detectorsfor detecting one or more markers on the roll of printed web product.The reel editor module is configured to determine a current position ofthe roll of printed web product based on the detected one or moremarkers. In some embodiments, the one or more markers are color markers.

In another example embodiment, a system for editing a roll of printedweb product is provided. The system comprises a controller and a memoryincluding computer program product stored thereon. The computer programproduct is configured, when executed by the controller, to receive acontrol plan associated with the roll of printed web product. Each rollof printed web product is associated with a roll-specific control plan.The control plan comprises roll data that includes data corresponding toone or more printed orders on the roll of printed web product. The rolldata comprises waste data that includes one or more locations of wastesections on the roll of printed web product. Each of the waste sectionscorresponds to at least one of waste on the roll of printed web productor unsatisfactory images that are printed on the roll of printed webproduct. The computer program product is further configured to control afirst winding device to unwind the roll of printed web product toposition a location of a waste section of the roll of printed webproduct at the cutting station for removal of the waste section to forman edited roll of printed web product. The computer program product isfurther configured to control at least one of the first winding deviceor a second winding device to wind the edited roll of printed webproduct after removal of the waste section. The computer program productis further configured to update, in the memory, the control planassociated with the roll of printed web product by updating the rolldata based on the removed waste sections to form an updated control planassociated with the edited roll of printed web product.

In some embodiments, the computer program product is further configured,when executed by the controller, to control at least one of the firstwinding device or the second winding device to unwind the edited roll ofprinted web product at a first winding station and rewind the editedroll of printed web product at a second winding station to form anupdated roll of printed web product that is rewound with a leading tailend on the outside circumference of the roll of printed web product.

In some embodiments, the roll data comprises a length of printed webproduct associated with an order section on the roll of printed webproduct, wherein each order section comprises at least one structureoutline and at least one corresponding printed image within the at leastone structure outline. Further, the computer program product is furtherconfigured, when executed by the controller, to update the control planby updating, in an instance in which a portion of an order section wasremoved, the roll data with an updated length of printed web productassociated with the order section.

In some embodiments, the roll data comprises a number of box outlinesassociated with an order section on the roll of printed web product,wherein each order section comprises at least one structure outline andat least one corresponding printed image within the at least onestructure outline. Further, the computer program product is furtherconfigured, when executed by the controller, to update the control planby updating, in an instance in which a portion of an order section wasremoved, the roll data with an updated remaining number of structureoutlines associated with the order section on the edited roll of printedweb product.

In some embodiments, in an instance in which the roll of printed webproduct is slit into one or more narrower rolls, the computer programproduct is further configured, when executed by the controller, toupdate the control plan by generating a control plan for each of the oneor more narrower rolls.

In yet another example embodiment, a method for editing a roll ofprinted web product is provided. The method comprises receiving acontrol plan associated with the roll of printed web product. Each rollof printed web product is associated with a roll-specific control plan.The control plan comprises roll data that includes data corresponding toone or more printed orders on the roll of printed web product. The rolldata comprises waste data that includes one or more locations of wastesections on the roll of printed web product. Each of the waste sectionscorresponds to at least one of waste on the roll of printed web productor unsatisfactory images that are printed on the roll of printed webproduct. The method further comprises controlling a first winding deviceto unwind the roll of printed web product to position a location of awaste section of the roll of printed web product at the cutting stationfor removal of the waste section to form an edited roll of printed webproduct. The method further comprises controlling at least one of thefirst winding device or a second winding device to wind the edited rollof printed web product after removal of the waste section. The methodfurther comprises updating, in the memory, the control plan associatedwith the roll of printed web product by updating the roll data based onthe removed waste sections to form an updated control plan associatedwith the edited roll of printed web product.

In some embodiments, the method further comprises controlling at leastone of the first winding device or the second winding device to unwindthe edited roll of printed web product at a first winding station andrewind the edited roll of printed web product at a second windingstation to form an updated roll of printed web product that is rewoundwith a leading tail end on the outside circumference of the roll ofprinted web product.

In yet another example embodiment, a method for determining whether ornot to edit waste from a roll of printed web product using a reel editoris provided. The method comprises receiving, from a vision system moduleof a manufacturing process, a control plan associated with the roll ofprinted web product. Each roll of printed web product is associated witha unique control plan. The control plan comprises roll data thatincludes order data and waste data. The waste data indicates one or morewaste sections on the roll of printed web product. Each of the one ormore waste sections corresponds to at least one of waste on the roll ofprinted web product or unsatisfactory images that are printed on theroll of printed web product. The order data corresponds to one or moreprinted orders on the roll of printed web product and includes at leastone of cost associated with processing material for the order, customerdata associated with the roll of printed web product, desired qualitydata associated with the roll of printed web product, or pricing dataassociated with the roll of printed web product. The method furthercomprises determining, by a processor, an amount of waste on the roll ofprinted web product based on the waste data of the control plan. Themethod further comprises determining, based on the order data of thecontrol plan, a waste tolerance threshold for the roll of printed webproduct. The method further comprises determining if the determinedamount of waste satisfies the determined waste tolerance threshold forthe roll of printed web product. The method further comprises, in aninstance in which the determined amount of waste satisfies thedetermined waste tolerance threshold for the roll of printed webproduct, providing an instruction to not edit the roll of printed webproduct at the reel editor such that no waste is removed via the reeleditor.

In some embodiments, the method further comprises, in an instance inwhich the determined amount of waste does not satisfy the determinedwaste tolerance threshold for the roll of printed web product, providingan instruction to edit the roll of printed web product at the reeleditor such that at least some of the waste is removed via the reeleditor.

In some embodiments, providing the instruction to not edit the roll ofprinted web product comprises causing a notification to not edit theroll of printed web product to be at least one of sent to or presentedon a display for an operator.

In some embodiments, providing the instruction to not edit the roll ofprinted web product comprises sending the control plan directly to acorrugator control module such that the control plan is not transmittedto a reel editor.

In some embodiments, the roll of printed web product comprises aplurality of order sections and each order section includes at least onestructure outline and at least one image printed within each structureoutline. The method further comprises determining an amount of waste bydetermining an amount of waste for each order section. The methodfurther comprises determining a waste tolerance threshold by determininga waste tolerance threshold for each order section. The method furthercomprises determining if the determined amount of waste satisfies thedetermined waste tolerance threshold by determining if the determinedamount of waste satisfies the determined waste tolerance threshold foreach order section. In some embodiments, providing the instruction tonot edit the roll of printed web product at the reel editor comprisesproviding the instruction in an instance in which the determined amountof waste satisfies the determined waste tolerance threshold for all ofthe order section on the roll of printed web product. In someembodiments, providing the instruction to not edit the roll of printedweb product at the reel editor comprises providing the instruction in aninstance in which the determined amount of waste satisfies thedetermined waste tolerance threshold for a predetermined number of ordersections on the roll of printed web product.

In some embodiments, determining the waste tolerance threshold comprisesdetermining the waste tolerance threshold based on a desired quality ofone or more orders on the roll of printed web product.

In some embodiments, determining the waste tolerance threshold comprisesdetermining the waste tolerance threshold based on an estimated cost ofremoving waste from the roll of printed web product using the reeleditor.

In some embodiments, determining the waste tolerance threshold comprisesdetermining the waste tolerance threshold based on a pricing of one ormore orders on the roll of printed web product.

In some embodiments, the method further comprises providing at least oneof waste data or an indication of a result of determining if thedetermined amount of waste satisfies the determined waste tolerancethreshold for the roll of printed web product to a customer insightmodule that is configured to generate one or more reports using thewaste data or the result.

In yet another example embodiment, a system for determining whether ornot to edit waste from a roll of printed web product using a reel editoris provided. The system comprises a controller and a memory includingcomputer program product stored thereon. The computer program product isconfigured, when executed by the controller, to receive, from a visionsystem module of a manufacturing process, a control plan associated withthe roll of printed web product. Each roll of printed web product isassociated with a unique control plan. The control plan comprises rolldata that includes order data and waste data. The waste data indicatesone or more waste sections on the roll of printed web product. Each ofthe one or more waste sections corresponds to at least one of waste onthe roll of printed web product or unsatisfactory images that areprinted on the roll of printed web product. The order data correspondsto one or more printed orders on the roll of printed web product andincludes at least one of cost associated with processing material forthe order, customer data associated with the roll of printed webproduct, desired quality data associated with the roll of printed webproduct, or pricing data associated with the roll of printed webproduct. The computer program product is further configured todetermine, by a processor, an amount of waste on the roll of printed webproduct based on the waste data of the control plan. The computerprogram product is further configured to determine, based on the orderdata of the control plan, a waste tolerance threshold for the roll ofprinted web product. The computer program product is further configuredto determine if the determined amount of waste satisfies the determinedwaste tolerance threshold for the roll of printed web product. Thecomputer program product is further configured to, in an instance inwhich the determined amount of waste satisfies the determined wastetolerance threshold for the roll of printed web product, provide aninstruction to not edit the roll of printed web product at the reeleditor such that no waste is removed via the reel editor.

In some embodiments, the computer program product is further configured,when executed by the controller, to, in an instance in which thedetermined amount of waste does not satisfy the determined wastetolerance threshold for the roll of printed web product, provide aninstruction to edit the roll of printed web product at the reel editorsuch that at least some of the waste is removed via the reel editor.

In some embodiments, the computer program product is further configured,when executed by the controller, to provide the instruction to not editthe roll of printed web product by causing a notification to not editthe roll of printed web product to be at least one of sent to orpresented on a display for an operator.

In some embodiments, the computer program product is further configured,when executed by the controller, to provide the instruction to not editthe roll of printed web product by sending the control plan directly toa corrugator control module such that the control plan is nottransmitted to a reel editor.

In some embodiments, the roll of printed web product comprises aplurality of order sections and each order section includes at least onestructure outline and at least one image printed within each structureoutline. The computer program product is further configured, whenexecuted by the controller, to determine an amount of waste bydetermining an amount of waste for each order section. The computerprogram product is further configured to determine a waste tolerancethreshold comprises determining a waste tolerance threshold for eachorder section. The computer program product is further configured todetermine if the determined amount of waste satisfies the determinedwaste tolerance threshold comprises determining if the determined amountof waste satisfies the determined waste tolerance threshold for eachorder section. In some embodiments, the computer program product isfurther configured, when executed by the controller, to provide theinstruction to not edit the roll of printed web product at the reeleditor by providing the instruction in an instance in which thedetermined amount of waste satisfies the determined waste tolerancethreshold for all of the order section on the roll of printed webproduct. In some embodiments, the computer program product is furtherconfigured, when executed by the controller, to provide the instructionto not edit the roll of printed web product at the reel editor byproviding the instruction in an instance in which the determined amountof waste satisfies the determined waste tolerance threshold for apredetermined number of order sections on the roll of printed webproduct.

In some embodiments, the computer program product is further configured,when executed by the controller, to determine the waste tolerancethreshold by determining the waste tolerance threshold based on adesired quality of one or more orders on the roll of printed webproduct.

In yet another example embodiment, a system for determining whether ornot to edit waste from a roll of printed web product using a reel editoris provided. The system comprises a first winding station comprising awinding device that is configured to wind and unwind the roll of printedweb product, wherein the first winding station is configured to receivethe roll of printed web product. The system further comprises a cuttingstation configured to enable one or more portions of the roll of printedweb product to be removed. The system further comprises a second windingstation that is configured to receive a tail end of the roll of printedweb product and enable winding and unwinding of the roll of printed webproduct. The system further comprises a reel editor module configured toreceive, from a vision system module of a manufacturing process, acontrol plan associated with the roll of printed web product. Each rollof printed web product is associated with a unique control plan. Thecontrol plan comprises roll data that includes order data and wastedata. The waste data indicates one or more waste sections on the roll ofprinted web product. Each of the one or more waste sections correspondsto at least one of waste on the roll of printed web product orunsatisfactory images that are printed on the roll of printed webproduct. The order data corresponds to one or more printed orders on theroll of printed web product and includes at least one of cost associatedwith processing material for the order, customer data associated withthe roll of printed web product, desired quality data associated withthe roll of printed web product, or pricing data associated with theroll of printed web product. The reel editor module is furtherconfigured to determine, by a processor, an amount of waste on the rollof printed web product based on the waste data of the control plan. Thereel editor module is further configured to determine, based on theorder data of the control plan, a waste tolerance threshold for the rollof printed web product. The reel editor module is further configured todetermine if the determined amount of waste satisfies the determinedwaste tolerance threshold for the roll of printed web product. The reeleditor module is further configured to, in an instance in which thedetermined amount of waste satisfies the determined waste tolerancethreshold for the roll of printed web product, provide an instruction tonot edit the roll of printed web product at the reel editor such that nowaste is removed via the reel editor.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 shows a block diagram of an example paper, sheet, and/or boxmanufacturing process, in accordance with some embodiments discussedherein;

FIG. 2 shows an example platform for various aspects of a corrugated boxmanufacturing process, in accordance with example embodiments describedherein;

FIG. 3A shows an example portion of a roll of web product with fourdifferent structure areas, in accordance with some example embodimentsdiscussed herein;

FIG. 3B shows an example portion of a roll of web product, wherein thestructure areas each include a readable marker, in accordance withexample embodiments described herein;

FIG. 4 shows a box diagram of an example reel editor, in accordance withexample embodiments described herein;

FIG. 5A shows an example reel editor with a cutting station, inaccordance with example embodiments described herein;

FIG. 5B shows a close up of an example cutting station, with an operatorperforming a cut of the roll of web product, in accordance with exampleembodiments described herein;

FIG. 6A shows a block diagram of an example corrugated sheet or boxmanufacturing process with print in-line with the corrugator, inaccordance with some embodiments discussed herein;

FIG. 6B shows a block diagram of an example corrugated sheet or boxmanufacturing process with print off-line or near-line, before thecorrugator, in accordance with some embodiments discussed herein;

FIG. 7A illustrates a portion of the corrugated box manufacturingprocess with print in-line with the corrugator, in accordance with someembodiments discussed herein;

FIG. 7B illustrates a portion of the corrugated box manufacturingprocess with print off-line or near-line, before the corrugator, inaccordance with some embodiments discussed herein;

FIG. 8 illustrates a cutting arrangement portion of the corrugated boxmanufacturing process, in accordance with some embodiments discussedherein;

FIG. 9 illustrates a three line mark typically seen in corrugated sheetor box manufacturing of pre-printed liner, in accordance with someembodiments discussed herein;

FIG. 10 shows an example portion of a layered corrugated board web,wherein the sheet or box structure areas of the board web each include acolor marker, in accordance with example embodiments described herein;

FIG. 11 shows another example portion of a layered corrugated board web,wherein the sheet or box structure areas of the board web each include acolor marker, in accordance with example embodiments described herein;

FIG. 12 shows yet another example portion of a layered corrugated boardweb, wherein the sheet or box structure areas of the board web eachinclude a color marker, and wherein some of the sheet or box structureareas include a readable marker, in accordance with example embodimentsdescribed herein;

FIG. 13 shows a block diagram of an example folded carton manufacturingprocess, in accordance with some embodiments discussed herein;

FIG. 14 shows a block diagram of an example industrial bag manufacturingprocess, in accordance with some embodiments discussed herein;

FIG. 15 shows a block diagram of an example cup manufacturing process,in accordance with some embodiments discussed herein;

FIG. 16 shows a block diagram of an example paper plate manufacturingprocess, in accordance with some embodiments discussed herein;

FIG. 17 illustrates a flowchart of an example method for editing a rollof printed web product, in accordance with some embodiments discussedherein; and

FIG. 18 illustrates a flowchart of an example method for determiningwhether or not to edit a roll of printed web product, in accordance withsome embodiments discussed herein.

DETAILED DESCRIPTION

Some example embodiments now will be described more fully hereinafterwith reference to the accompanying drawings, in which some, but not allexample embodiments are shown. Indeed, the examples described andpictured herein should not be construed as being limiting as to thescope, applicability or configuration of the present disclosure. Rather,these example embodiments are provided so that this disclosure willsatisfy applicable legal requirements. Like reference numerals refer tolike elements throughout.

Example Paper, Sheet, or Box Manufacturing Process

FIG. 1 illustrates an example paper, sheet, or box manufacturing process10 to form one or more paper-based products, according to variousembodiments of the present invention. The manufacturing process 10includes a number of phases that result in a finished product that isshaped and printed per the customer's order. The process 10 may includean ordering phase 12, a planning phase 14, a print phase 30, a reeleditor phase 40, a sheet formation/processing phase 60, a finishingphase 70, and a tracking/logistics phase 80.

Depending on the desired configuration, one or more controller(s) 90 maybe used to control one or more various phases (e.g., varioussystems/devices therein) of the manufacturing process 10. In someembodiments, less or more phases or different orders of phases arecontemplated. Some embodiments of the present invention are contemplatedfor any type of paper, sheet, or box product manufacturing, includingprinted paper-based product manufacturing, such as corrugate, foldedcarton, beverage labels, flexible paper, industrial bags, plates, cups,décor, and many others.

In some embodiments, the controller 90 may be configured to controloperation of one or more printing presses during the printing phase 30,operation of one or more reel editor(s) for one or more lanes during thereel editor phase 40, operation of various components used during thesheet formation/processing phase 60, and/or operation of variouscomponents used during the finishing phase 70. Likewise, the controller90 may be used with the ordering phase 12 and/or during thetracking/logistics phase 80, such as described herein. In someembodiments, the controller 90 may be spread over any number ofcontrollers at any of the various phases of the manufacturing process10.

As described in more detail herein, the controller 90 provides logic andcontrol functionality used during operation of various components/phasesof the manufacturing process 10. In some embodiments, the functionalityof the controller 90 may be distributed to several controllers that eachprovides more limited functionality to discrete portions of theoperation of manufacturing process 10.

The controller 90 may comprise one or more suitable electronicdevice(s)/server(s) capable of executing described functionality viahardware and/or software control. In some embodiments, the controller 90may include one or more user interfaces (not shown), such as fordisplaying information and/or accepting instructions. The controller 90can be, but is not limited to, a microprocessor, microcomputer, aminicomputer, an optical computer, a board computer, a complexinstruction set computer, an ASIC (application specific integratedcircuit), a reduced instruction set computer, an analog computer, adigital computer, a molecular computer, a quantum computer, a cellularcomputer, a solid-state computer, a single-board computer, a bufferedcomputer, a computer network, a desktop computer, a laptop computer, apersonal digital assistant (PDA) or a hybrid of any of the foregoing.

The controller 90 may include one or more processors coupled to a memorydevice. Controller 90 may optionally be connected to one or moreinput/output (I/O) controllers or data interface devices (not shown).The memory may be any suitable form of memory such as an EPROM (ErasableProgrammable Read Only Memory) chip, a flash memory chip, a disk drive,or the like. As such, the memory may store various data, protocols,instructions, computer program code, operational parameters, etc. Inthis regard, controller may include operation control methods embodiedin application code. These methods are embodied in computer instructionswritten to be executed by one or more processors, typically in the formof software. The software can be encoded in any suitable language,including, but not limited to, machine language, assembly language, VHDL(Verilog Hardware Description Language), VHSIC HDL (Very High Speed ICHardware Description Language), Fortran (formula translation), C, C++,Visual C++, Java, ALGOL (algorithmic language), BASIC (beginnersall-purpose symbolic instruction code), visual BASIC, ActiveX, HTML(HyperText Markup Language), and any combination or derivative of atleast one of the foregoing. Additionally, an operator can use anexisting software application such as a spreadsheet or database andcorrelate various cells with the variables enumerated in the algorithms.Furthermore, the software can be independent of other software ordependent upon other software, such as in the form of integratedsoftware. In this regard, in some embodiments, the controller 90 may beconfigured to execute computer program code instructions to performaspects of various embodiments of the present invention describedherein.

In the ordering phase 12, a customer may supply an order that includesdesired characteristics for the end product. For example, the customermay provide a number of desired sheet, paper, or box structures(including for example labels, cartons, bags, plates, cups, décor,etc.), shape requirements, one or more images/designs for printing onthe structures, color specifications, among many others. In someembodiments, the customer may input such an order through a webinterface. The web interface may enable the customer to easily input thedesired characteristics of the order electronically, such as forming adesign for the desired end product(s). The web interface may also enablethe customer to perform many related tasks, including, for example,updating orders, tracking orders, handling payment, requestingassistance, setting up automated ordering (e.g., recurring ordering),viewing and approving example images (“soft proofing”), viewing exampleend products, etc.

In addition to providing increased efficiency of process for thecustomer, the web interface may also directly interact with and provideinformation for automated processes useful in the remainder of themanufacturing process 10. For example, the information from the webinterface may be fed directly into a controller 90 and utilizedaccordingly. For example, as described herein, the information from theweb interface may be used to form a control plan (e.g., reel map, printplan, process plan, etc.) for a planned roll of web product (such as maybe used to form the desired end product(s)). Additionally, however, theinformation from the web interface may be used to provide on-the-flyupdates or adjustments to the manufacturing process. Further, feedback(e.g., from the controller 90) may be provided back to the web interfacefor the customer, such as tracking information, images of the completedsheet or box structures, among other things.

In some embodiments, the controller 90 may be configured to aggregatereceived orders, such as in one or more databases.

In some embodiments, the controller 90 (such as during the planningphase 14) may be configured to generate (e.g., form) a control planassociated with a roll of web product. In some embodiments, a controlplan may be electronic-based (e.g., an electronicmap/plan/table/listing/etc.) that is reference-able for determining howthe various components of the manufacturing process 10 shouldoperate—such as to form the desired product through the manufacturingprocess 10.

In some embodiments, the controller 90 may be configured to generate acontrol plan associated with a roll of web product for at least oneorder for the one or more paper-based products from among a plurality oforders. In this regard, each order of the plurality of orders maycomprise at least one design for at least one paper-based product, andthe design may include one or more printed images (such as for beingprinted on the desired product).

In some embodiments, the control plan includes one or more sets of orderinstructions. In some embodiments, each set of order instructions maycorrespond to a different order that is planned to be manufactured usingthe generated control plan. For example, a control plan may include aset of first order instructions for forming a first paper-based productfrom the roll of web product for fulfilling a first order. Additionally,in some embodiments, a control plan may have a second or more sets oforder instructions, such as to control manufacturing of additionalproducts. In some cases, depending on the size restrictions of the orderand/or the systems used during the manufacturing process, the controlplan may be generated such that different orders are positioned orplanned to be adjacent to each other in a width direction (e.g., next toeach other) on a roll of web product. Additionally or alternatively, thecontrol plan may be generated such that different orders are positionedor planned to run one after the other in a length direction on a roll ofweb product.

The order instructions for the control plan for each order may includeone or more instructions, specification, databases, etc. for enablingcontrol and/or operation of various systems/devices of the manufacturingprocess 10. For example, the set of first order instructions maycomprise first plan instructions for forming one or more first sheet orbox structure areas on the roll of web product. Further, the first planinstructions may include one or more printed images for each of thefirst sheet or box structure areas. Ultimately, in some embodiments, theplan instructions (and other instructions) that form the set of orderinstructions may be used during the manufacturing process 10 to form thedesired product.

In some embodiments, a control plan (such as through the planinstructions) may provide a layout of the order and/or arrangement ofsheet or box structure areas on a roll of web product that are to beprinted on, formed, and/or cut during the manufacturing process 10. Forexample, a control plan (e.g., reel map) for the section of web product220 shown in FIG. 3A may include indications that there should be 4structures (A, B, C, and D) that are arranged as shown. In someembodiments, the control plan (or a portion thereof) may berepresentable in visual form, such as to a person (or persons), whichmay be useful for manually checking the control plan for accuracy,efficiency, and/or operating the corrugator. In some embodiments,electronic verification of such checking could occur either with orwithout the visual representation of the control plan.

The manufacturing process 10 may also including the printing phase 30.Depending on the desired manufacturing process 10, digital printprocesses can be used, providing for enhanced image quality. During theprinting phase 30, the controller 90 may direct the press digital frontend (DFE) and raster image processor (RIP), etc., to print one or moreimages at specific locations on the web product. In some embodiments,the controller 90 may utilize the control plan to determine where on theweb to print the images and/or markers. In some embodiments, thecontroller 90 may provide the control plan to the printer for operationthereof to cause the printer to print the desired image at anappropriate position on the roll of web product (e.g., within each sheetor box structure area)—thereby forming a roll of printed web product.For example, an image selected by the customer (such as a bottle), maybe printed in the center (or other section) of a structure—such as mayultimately be visible for marketing or other purposes once the structureis formed. Any image (including, words, marks, instructions, etc.) iscontemplated by various embodiments of the present invention.

In some embodiments, one or more markers can be printed on the webproduct, including any marker that may be used by various components ofthe manufacturing process 10, such as for tracking, cutting, printing,etc. Further description regarding possible markers and theirutilization is provided in greater detail herein. In this regard, thecontroller 90 may be connected to one or more vision systems that areused to read or detect color, defects, structure, and various markersfor controlling and/or operating various components/phases of themanufacturing process 10.

During the reel editor phase 40, the controller 90 may direct operationof a reel editor to edit (e.g., remove) waste from the roll of printedweb product. For example, the controller 90 (such as during the printphase 30 and/or a separate/different phase) may be configured todetermine waste that is on the roll of printed web product. Such wastecould be unprinted sections of the roll and/or poor qualityimages/defects in the roll.

In some embodiments, the controller 90 is configured to provide thecontrol plan to at least one reel editor for controlling operation ofthe reel editor. In such an example embodiment, the control plan mayinclude editing instructions (e.g., within the set of orderinstructions) to control operation of the reel editor to cause one ormore portions of the roll of printed web product to be removed. In someembodiments, the editing instructions may cause the reel editor to slitthe roll of web product into more than one child roll (e.g., narrower inpaper width) and/or to break the roll of web product into more than onechild roll (e.g., narrower in paper roll diameter). Such child rolls maybe designed for processing through various manufacturing systemsdownstream and may, in some instances, assist in tracking and/or ordermanagement.

Once edited, the controller 90 may determine and update the control planto account for any removed waste and/or one or more newly formed childroll(s).

During the sheet formation/processing phase 60, the controller 90 may beconfigured to perform one or more processes to form and/or process theroll of web product in formation of the desired end product. In someembodiments, the controller 90 may be configured to provide the controlplan to at least one sheet formation/processing system for controllingoperation of the sheet formation/processing system. The sheetformation/processing system may include one or more systems for theformation/processing of the roll of web product, such as forming theroll of web product into one or more sheets (or structures) that may beutilized in the remainder of the manufacturing process 10.

As used herein, “sheet formation/processing” may refer to any formationor processing of a sheet or structure from a roll of web product, suchas for example cutting/forming a rectangular shaped structure that canbe, in some embodiments, further processed (e.g., in the finishingphase) to form (or help form) one or more paper-based products. In someembodiments, during the sheet formation/processing phase 60, the roll ofweb product (or portions thereof) may be formed into additional layeredproduct that can be cut into sheets, such as when processed through acorrugator. In some embodiments, further processing may occur during thesheet formation/processing phase 60 and/or finishing phase 70. Forexample, the formed sheet may be die-cut, such as during either phase.

In some embodiments, the sheet formation/processing system may include aweb forming device that is configured to use the roll of printed webproduct to form an updated web. The control plan (such as in the set oforder instructions) may include web forming instructions to controloperation of the web forming device to cause the updated web to beformed. In some example embodiments, the updated web may includeadditional layers of material (e.g., additional webs for added support,glue, fluting, lamination, etc.). In this regard, the updated web may beused for forming the desired end product.

In some embodiments, the sheet formation/processing system may includeat least one cutting arrangement (e.g., one or more cutting devices)that is configured to cut a portion of the roll of printed web product.The control plan (such as in the set of order instructions) may includecutting instructions to control operation of the cutting arrangement tocause one or more sheet or box structures with the printed image thereinto be cut from the roll of printed web product. In such an example, theone or more sheet or box structures with the first printed image thereinmay then be utilized to form the desired paper-based product forfulfilling the order.

For example, as described in greater detail herein, an examplemanufacturing process is corrugated box manufacturing and thatmanufacturing process may include a board making phase and/or cuttingphase (see e.g., FIGS. 4A and 4B). In such an example, the board makingphase may be performed under operation of one or more web formingdevices (e.g., using a corrugator). Additionally, the cutting phase maybe performed under operation of one or more cutting devices (e.g., usinga corrugator). In some embodiments, other manufacturing processes arealso contemplated—providing different sheet formation/processing phases60, such as for use with carton formation, plate formation, cupformation, bag formation, etc.

Referring back to FIG. 1, with the sheets formed/processed, themanufacturing process 10 may continue to the finishing phase 70. Thefinishing phase 70 may include additional printing, additional cutting(e.g., die-cutting), additional scoring, additional gluing, and/or othernecessary functions to achieve a finished product for sending to thecustomer.

In some embodiments, the controller 90 is configured to provide thecontrol plan to at least one finishing system for controlling operationof the finishing system. The control plan (such as in the set of orderinstructions) may include finishing instructions to control operation ofthe finishing system to cause one or more products to be formed, such asusing the sheets from the sheet formation/processing phase.

In some embodiments, the finishing system may comprise a die-cutter forforming a shaped sheet and/or product. In such an example, the finishinginstructions from the control plan may cause the die-cutter to cut thesheet and/or roll from the sheet formation/processing phase 60 into adesired shape.

In some embodiments, the finishing system may comprise a folding/gluingdevice that is configured to fold and/or glue the one or more sheet orbox structures for use in formation of the one or more desired products(e.g., folded cartons). In such an example, the finishing instructionsfrom the control plan may cause the folding device to fold and glue theone or more sheet or box structures into the one or more folded cartons.

In some embodiments, the finishing system may comprise a tuber devicethat is configured to form the one or more sheet or box structures intoone or more tubes and/or a bottoming device that is configured to form abottom for each of the one or more tubes for use in formation of thedesired products (e.g., an industrial bag). In such an example, thefinishing instructions from the control plan may cause the tuber deviceto form the one or more sheet or box structures into one or more tubesand the bottoming device to form a bottom of each tube for use information of the desired product.

In some embodiments, the finishing system may comprise a cup formingdevice that is configured to form the one or more sheet or boxstructures into one or more desired products (e.g., cups). In such anexample, the finishing instructions from the control plan may cause thecup forming device to form the one or more sheet or box structures intoone or more cups.

In some embodiments, the finishing system may comprise a plate formingdevice that is configured to form the one or more sheet or boxstructures into one or more desired products (e.g., paper plates). Insuch an example, the finishing instructions from the control plan maycause the plate forming device to form the one or more sheet or boxstructures into one or more plates.

In some embodiments, the controller 90 is configured to determine if theone or more products formed by the finishing system satisfy a particularorder. For example, in some embodiments, a vision system or other visualinspection system may be used to confirm accuracy and/or separating ofthe order(s) during the manufacturing process.

The manufacturing process 10 may also include a tracking/logistics phase80 that includes tracking the finished sheet or box structures and/orpreparing/delivering them to the customer. In some embodiments, one ormore tracking or counting systems can be implemented upstream in themanufacturing process 10, such as to enable tracking/logistic planningthroughout the manufacturing process 10. In such a regard, in someembodiments, the controller 90 is configured to track one or morewebs/sheets/products during the manufacturing process 10. In someembodiments, unique codes based on the product type (e.g., corrugate,folded carton, industrial bag, plate, cup, décor, etc.) may be used todifferentiate control plans and manufacturing processes.

Example Platform for Managing Manufacturing

FIG. 2 illustrates an example platform 100 for managing paper, sheet, orbox manufacturing according to various embodiments of the presentinvention. Though some of the following description is provided forexample corrugated box manufacturing, some embodiments of the presentinvention contemplate use of the platform (or various aspects of theplatform) for any product manufacturing, such as corrugated boxes,folded carton, beverage containers, labels, flexible paper, industrialbags, plates, cups, décor, and many others.

The platform 100 includes a number of platform modules that interactwith each other to form an integrated platform that provides efficientmanufacturing processes. In the depicted embodiment, the platform 100includes a web interface module 105, a structure module 110, a graphicsfile workflow module 115, a graphics file management module 120, amanagement information systems (MIS) module 125, an imposition enginemodule 130, a variable data engine module 135, a press module 140, acolor management module 148, a press vision system module 145, a reelmanifest module 150, a customer insights module 152, a reel editormodule 155, a corrugator controls module 160, and an enterprise resourceplanning (ERP)/corrugator planning module 165. As described herein, thevarious modules each contain features that are designed to work togetherto provide an integrated, efficient platform 100 for manufacturingcorrugated sheet or box structures for customers. In some embodiments,the controller 90 may be configured to communicate with and/or controloperation of many of the various modules. While the depicted embodimentshows various particular modules, some embodiments of the presentinvention contemplate many variations, including additional modules andcombinations in whole or part of shown modules to form a platform.

The web interface module 105 may be configured to provide forinteraction between customers, users, and the platform 100. For example,the web interface module 105 may be configured to provide an interfacefor a customer to provide information to the platform 100, such asorders, changes to orders, payments, etc. The web interface module mayalso enable additional features, such as enabling a customer to printsamples, upload their own art/images, track orders, among other things.Additionally, however, the web interface module 105 may be helpful forinternal use, such as for tracking sales. The internal web interface maydisplay pertinent information to the company, such as trends, etc. Theweb interface module 105 may communicate, for example, with thestructure module 110, the workflow module 115, the managementinformation systems module 125, and/or the ERP/corrugator planningmodule 165.

The structure module 110 may be configured to enable selection anddesign of the structures planned for manufacture. For example, thestructure module 110 may enable selection of the types of boxes (e.g.,the material, number of layers, flute medium, etc.). Additionally, thesize and shape of the sheet or box structure may be configured using thestructure module 110. In some embodiments, preferred structurespecifications may be stored by the structure module 110. Further, rulesor other constraints may be communicated to the customer and/or utilizedin determination of the sheet or box structure specifications. Thestructure module 110 may communicate, for example, with the webinterface module 105, the workflow module 115, and/or the graphics filemanagement module 120.

The workflow module 115 may be configured to help process the flow ofgraphics orders and facilitate input of the orders into the structuremodule 110 and the graphics file management module 120. In this regard,the workflow module 115 may communicate with the web interface module105, the structure module 110, and/or the graphics file managementmodule 120.

The graphics file management module 120 may be configured to helpprocess the graphics files for use in designing and printing on thesheet or box structures. For example, the graphics file managementmodule 120 may include a repository of available images. Likewise, thegraphics file management module 120 may store new images uploaded by thecustomer. Further, the graphics file management module 120 may includerules or other feature constraints that can be communicated to thecustomer and/or implemented when forming the orders. The graphics filemanagement module 120 may communicate, for example, with the structuremodule 110, the workflow module 115, the management information systemmodule 125, the color management module 148, and/or the impositionengine 130.

The management information system module 125 may be configured to store,process, and organize the information for the platform 100. For example,the management information systems module 125 is configured to receiveand organize the orders, other customer requests, and internalinformation from the web interface module 105. Further, the data fromthe graphics file management module 120, imposition engine module 130,and enterprise resource planning (ERP)/corrugator planning module 165may be stored and organized using the management information systemsmodule 125. The management information systems module 125 maycommunicate, for example, with the web interface module 105, thegraphics file management module 120, the imposition engine 130, and/orthe ERP/corrugator planning module 165.

The enterprise resource planning (ERP)/corrugator planning module 165may be configured to facilitate planning and implementation of themanufacturing process. In this regard, the ERP/corrugator planningmodule 165 may receive data from various features of the platform 100and process the information to plan out efficient manufacturingprocesses across the entire platform. For example, the ERP/corrugatorplanning module 165 may receive data from the web interface module 105,the management information systems module 125, the press module 140, thevision system module 145, the corrugator controls module 160, and reeleditor module 155 to inform planning for future jobs. As an example, themanagement information systems module 125 may provide order informationto the ERP/corrugator planning module 165, which can be utilized to formjob tickets for the imposition engine module 130. The ERP/corrugatorplanning module 165 may also be configured to enable printing ofschedules for jobs etc.—which may be used for tracking or otherpurposes. Such information, for example, may be used to provideinformation back to the customer, such as through the web interfacemodule 105. The ERP/corrugator planning module 165 may communicate, forexample, with the web interface module 105, the management informationsystems module 125, the imposition engine module 130, the press module140, the vision system module 145, the reel editor module 155, and/orthe corrugator controls module 160.

The imposition engine module 130 may be configured to plan outimposition of print objects (e.g., images or markers) and other variabledata on the roll of web product. For example, the imposition enginemodule 130 may gather ready job tickets (e.g., customer orders), such asfrom the management information systems module 125 and/or ERP/corrugatorplanning module 165, for imposition across rolls of web product. Usingthe job tickets, the imposition engine module 130 may determine layoutsfor the webs that minimize waste and improve processes. In order to planout and finalize impositions, the imposition engine module 130 mayreceive information from various other modules, such as the graphicsfile management module 120, the variable data engine module 135, and thereel manifest module 150.

In some embodiments, the imposition engine module 130 may provide theability to test roll layouts and finalize acceptable roll layouts. Inthis regard, formation of the layouts may be optimized based on manydifferent factors, including, for example, roll/sheet/finished boxrequirements, press limitations, downstream corrugation, die-cutoptimization, among other things. After finalization, the impositionengine module 130 may be configured to pass the imposed layout to thepress module 140 for printing.

The imposition engine module 130 may communicate, for example, with thegraphics file management module 120, the management information systemsmodule 125, the ERP/corrugator planning module 165, the variable dataengine module 135, the reel manifest module 155, and the press module140.

The variable data engine module 135 may be configured to manage markersand other variable data through the manufacturing process. As describedherein, some embodiments of the present invention contemplate use ofmarkers for automated control during the manufacturing process, such forautomated control/operation of the reel editor. Depending on theconfiguration of the manufacturing process, different markers or othervariable data may be utilized to achieve automated control. The variabledata engine module 135 may be configured to track, organize, determine,and report on such markers or other variable data.

In some embodiments, the variable data engine module 135 may be aweb-based back-office function that assigns/allocates, references,and/or reports on variable data/marker information utilization. Such amodule may enable generation and allocation of group (multi-use)individual barcodes, quick response (QR) codes, watermarks, colormarkers, and general variable data. In some embodiments, the variabledata engine module 135 may assign/allocate variable data/markers byvarious entities, such as brand, product type, printer type, convertertype, corrugator, logistics supply chain, or other factors.

In some embodiments, the variable data engine module 135 may transfersuch information to the imposition engine module 130 for imposing on theboard or web layout. In some embodiments, downstream information can beprovided back to and utilized by the variable data engine module 135,such as information from the vision system module 145, reel editormodule 155, corrugator, finishing equipment, logistics control,retailer, brand, and/or customer. Likewise, status updates can beprovided to and from the variable data engine module 135.

In some embodiments, the data generated by the variable data enginemodule 135 may be tracked and utilized for reporting and determinationof optimized processes. Further analytics and usage reporting may begenerated. Along these lines, such information and leanings may beapplicable to manufacturing of other products, such as also contemplatedherein.

The variable data engine module 135 may communicate, for example, withthe graphics file management module 120, the imposition engine module130, the customer insights module 152, and the press module 140.

The press module 140 may be configured to print objects (e.g., imagesand markers) on the roll of web product, such as during the printingphase 30 described herein. Depending on capabilities of the press,different image qualities and efficiencies may be achieved. The pressmodule 140 may be configured to communicate with, for example, theimposition engine module 130, the variable data engine module 135, thereel manifest module 150, the vision system module 145, and the colorprofiles module 148.

The color management module 148 may be configured to store and providecolor profile information for the press module 140. In this regard, thecolor profiles module 148 may manage specific color profiles forcustomers, presses, substrates, or other requirements, that are thenused by the press during printing. The color management module 148 maybe configured to communicate with, for example, the graphics filemanagement module 120 and the press module 140.

The vision system module 145 may be configured to perform many differenttypes of vision (e.g., detection) related functions during themanufacturing process 10. In this regard, the vision system module 145may be configured for use during the printing process and/or during useof the reel editor or other components of the manufacturing process 10.In describing such an example vision system module 145, some embodimentsof the present invention contemplate separating described functions ofthe vision system module. For example, a portion of the vision systemmodule 145 may be used during the printing process, while anotherportion of the vision system module 145 may be used in conjunction withoperation of the reel editor or other component. Likewise, there may beseparate functions performed by separate vision system relatedcomponents (e.g., a visual inspection system may inspect the sheet orbox structures for accuracy and a detector may detect one or moremarkers). As such, though described as one module, the followingdescription is not meant to limit the structure of the modules of theplatform 10, as there may be separate vision related modules asappropriate.

The vision system module 145 may be configured to detect informationduring the manufacturing process, such as during use of the printingprocess. In some embodiments, the vision system module 145 may beconfigured to detect possible defects and/or confirm accuracy of printjobs. In such a regard, high quality can be maintained (e.g., confirmingcolor consistency on orders). For example, the vision system module 145may detect defects, such as serious banding, print registrationcolor-to-color, spit-on-page issues, bar/QR code scanability, over-printvarnish issues.

In some embodiments, the vision system module 145 may be configured todetect information during the manufacturing process 10, including duringthe printing phase 30, reel editor phase 40, and/or productformation/processing phase 60. For example, the vision system module 145may detect any defects or issues with the various components of themanufacturing process 10 (e.g., the printer, reel editor, or othercomponent). Additionally, the vision system module 145 may communicatepotential issues in real time to the controller 90 to adjust operationto address any issues. By detecting and communicating such issues, thecontroller 90 may adapt operation to avoid unnecessary waste. Alongthese lines, in some embodiments, the controller 90 may work with thevarious modules of the platform 100 to switch production, such as to adifferent portion of a reel map to avoid down time. In this regard, thevision system module 145 provides for the ability for on-the-flyadjustments during the manufacturing process.

In some embodiments, the vision system module 145 may be configured todetect various markers as the roll of web product progress throughvarious components (e.g., through the printer, reel editor, acorrugator, etc.). Based on the detected markers, the vision systemmodule 145 may provide information to the controller 90 foroperation/control accordingly. Further, such information can be used fortracking orders and status.

In some embodiments, photographs (e.g., digital images) can be taken andstored for evidence or additional learning. In some embodiments, thephotographs could be automatically provided to the customer forverification and auditing purposes.

In some embodiments, the vision system module 145 is configured toupdate the graphics file management module 120 to store and/or accessgolden reference images for print quality comparison.

The vision system module 145 may be configured to communicate, forexample, with the press module 140, the customer insights module 152,the reel manifest module 150, and/or the ERP/corrugator planning module165.

The customer insights module 152 may be configured to determine insightsthat may be useful for obtaining efficiencies, such as for a customer.The insights may be related to, for example, trends for customers,trends that the customer may find desirable, suggestions for thecustomer for future orders, etc. Additionally or alternatively, theinsights may be related to achieving efficiencies for preparing productfor specific customers. For example, the customer may indicate thatcertain “defects” are not important or not really defects as recognizedby the vision system module 145.

In some embodiments, the customer insights module 152 may track andutilize non-customer specific information, such as for determininggeneral efficiencies of process. For example, the module may trackvariable data/marker usage, reel map trends and usages, printer data,print head usage, paper waste, etc., such as to help form insights toincrease efficient manufacturing processes.

The customer insights module 152 may be configured to communicate with,for example, the variable data engine 135, the vision system module 145,and/or the reel manifest module 150.

The reel manifest module 150 may be configured to store and/or track theprocess flow (e.g., reel map) for the manufacturing process. The reelmanifest module 150 works with the imposition engine module 130 to storethe job layouts for operation during the manufacturing process 10. Thereel manifest 150 may be checked, such as by the controller 90, to helpdetermine the current position on a reel map—such as in response toreceiving a detection (e.g., a marker or a defect) from the visionsystem module 145. Further, the corresponding information needed tooperate the corrugator according to the reel map may be stored at thereel manifest module 150 and provided to the controller 90 so that thecontroller 90 may operate the corrugator accordingly. The reel manifestmodule 150 may work with the reel editor module 155 to edit the reel mapin real time, such as described herein. The reel manifest module 150 maybe configured to communicate with, for example, the customer insightsmodule 152, the imposition engine module 130, the press module 140, thevision system module 145, the corrugator controls module 160, and/or thereel editor module 155.

The reel editor module 155 may be configured to enable editing of theprocess flow, such as the reel map. In this regard, in some embodiments,the reel editor module 155 interacts with the reel manifest module 150to update the stored reel map. In some embodiments, the reel editormodule 155 may work with the vision system module 145 to identifyunnecessary waste, which can be edited from the reel map, such as basedon instructions for the controller 90. Such example information can alsobe provided to the ERP/corrugator planning module 165 to update the reelmap and/or for consideration in future jobs. The reel editor module 155may be configured to communicate, for example, with the reel manifestmodule 150, the vision system module 145, and the ERP/corrugatorplanning module 165.

In some embodiments, a reel editor may be configured to edit the rollbased on waste and/or errors that occurred during various manufacturingprocesses (e.g., during printing). For example, the controller 90 and/orreel editor module 155 may determine that some of the printed images aretoo poor quality and, thus, may edit the roll, such as by removing suchcorresponding structures with the poor quality images. Likewise, theroll of printed web product may be edited to remove the waste to form amore efficient roll. Accordingly, the reel map could be updated toaccount for the edits.

In some embodiments, the reel editor may be configured to determine ifthere is enough waste on the roll to even making editing worthwhile. Forexample, various factors may be checked to determine if there is enoughwaste or poor quality to warrant editing of the roll. In such a regard,certain rules and/or thresholds may be applied in order to determinewhether or not to edit the roll. Such rules and/or thresholds may beeffected by various factors, such as desired quality of the images,customer requirements, different price points, cost to edit the roll,board grade, among other possible factors.

In some embodiments, depending on the configuration, the reel editor maybe integrated with various manufacturing components (e.g., the printer,a corrugator, etc.).

The corrugator controls module 160 may be configured to controloperation of the corrugator, such as described herein. In someembodiments, the corrugator controls module 160 may work with one ormore cameras/detectors to detect information (e.g., markers or defects)that can be used to control/adjust operation of the corrugator. Forexample, the cameras/detectors may detect a marker and the corrugatorcontrols module 160 may determine how to operate the corrugator based onthe detected marker (and/or the corresponding position of the reel map).Then, based on the determined desired operations, the corrugatorcontrols module 160 may cause operation of the corrugator. For example,the corrugator controls module 160 may cause one or more knives tochange position and/or perform a cut. Additional information regardingcontemplated control through detection of markers is provided in greaterdetail herein. The corrugator controls module 160 may be configured tocommunicate with, for example, the reel manifest module 150, the visionsystem module 145, and the ERP/corrugator planning module 165.

In some embodiments, other components/machines and their correspondingcontrols may replace the corrugator, such as components/machines gearedtoward manufacturing of other products.

Example Structures and Orders for a Roll of Web Product

FIG. 3A shows an example arrangement of structures A, B, C, and D on aroll of web product 220, such as after the printing phase 30, and may,in some embodiments, form a representation of a control plan. Prior toprinting, however, the roll of web product is blank such that there isno information thereon. In this regard, the controller 90 operates thevarious components of the printing phase 30 to form printed imagesand/or markers on the blank roll of web product to begin forming thedesired structures. In the depicted example of FIG. 3A, the portion ofthe roll of web product 220 includes a number of first structures (A,291), a number of second structures (B, 292), a number of thirdstructures (C, 293), and a number of fourth structures (D, 294). Theroll of web product 220 also includes some unused (scrap) sections 299and potentially some waste between order changes down web, such asbetween structures A/B and structures C/D (though not shown in theexample of FIG. 3A).

In some embodiments, the present invention contemplates use of areadable marker to enable efficient control and/or operation of variouscomponents of the manufacturing process 10. The present invention, insome embodiments, contemplates utilizing one or more markers on the rollof web product that is printed on the press and “read” to enable controlof the various components of the manufacturing process 10. By “reading”the marker, the controller 90 can determine how to operate—such as byreferring to a control plan associated with the roll of printed webproduct and determining the position along the control plan by virtue ofthe read marker. The marker can also be used in tracking the boxes forpositioning in proper stacks and/or determining completion status of anorder. The present invention contemplates many different types ofmarkers (e.g., QR codes, bar codes, color marks, instructionsthemselves, etc.).

FIG. 3B illustrates an example portion of a roll of web product 220′that includes readable markers 270 a-d. Notably, each structure includesa different readable marker. For example, structure A, 291 has acorresponding readable marker 270 a; structure B, 292 has acorresponding readable marker 270 b; structure C, 293 has acorresponding readable marker 270 c; and structure D, 294 has acorresponding readable marker 270 d. Though the depicted embodimentshows the readable marker positioned within a sheet or box structure, insome embodiments, the readable marker may be positioned in the marginsor other waste area, but still associated with the correspondingstructure (or order section with the one or more structures).

One or more detectors 210 may be positioned along the pathway throughthe various components operating for the roll of web product (e.g., aprinter, a reel editor, a corrugator, finishing, etc.). In this regard,the one or more detectors 210 may be configured to “read” or detect themarker and provide that information to the controller 290 (e.g.,controller 90). The controller 290 may then be configured toautomatically control the various components of the manufacturingprocess 10 accordingly.

Depending on the desired configuration, some embodiments of the presentinvention contemplate different methods for obtaining information fromthe readable marker. For example, the readable marker may be a QR codeand cause automatic gathering of instructions for how the corrugatorshould operate based on following a link or other redirection methodprovided by the QR code. Similarly, other readable markers may cause thecontroller 290 to use a look-up table or other correlation means todetermine how to operate the corrugator. In some embodiments, the markermay include instructions in the marker itself. For example, positioncoordinates corresponding to a desired position for one or more knivesof a corrugator may form part of the marker. In such embodiments, thereis no need for a look-up table.

Example Reel Editor

With reference to FIG. 4, an example reel editor 340 for use in theexample manufacturing process 10 may comprise hardware and/or softwarecapable of performing one or more functions described herein. In thisregard, the reel editor 340 may include a controller 392 (which may beembodied as or with controller 90 described herein), a memory 394, acommunication interface 396, a user interface 398, a first windingstation 341, a second winding station 343, and a cutting station 345.

The controller 392 may be any means configured to execute variousprogrammed operations or instructions stored in a memory device such asa device or circuitry operating in accordance with software or otherwiseembodied in hardware or a combination of hardware and software, therebyconfiguring the device or circuitry to perform the correspondingfunctions of the controller 392 as described herein. In this regard, thecontroller 392 may be configured to perform operations described herein,such as with respect to example reel editor modules described herein.

The memory 394 may be configured to store instructions, computer programcode, reel map data, and other data/information associated with the reeleditor 340 in a non-transitory computer readable medium for use, such asby the controller 392.

The communication interface 396 may be configured to enable connectionto external systems (e.g., an external network 312, a computer server,and/or one or more other system(s)/device(s), such as from themanufacturing process 10). In some embodiments, the communicationinterface 396 may comprise one or more transmitters configured totransmit, for example, one or more signals according to exampleembodiments described herein. Likewise, the communication interface 396may include at least one receiver configured to, for example, receivedata according to example embodiments described herein. In someembodiments, the transmitter and receiver may be combined as atransceiver. In this regard, the communication interface 396 may beconfigured for wired and/or wireless communication. In some embodiments,the communication interface 396 may comprise wireless capabilities forWiFi, Bluetooth, or other wireless protocols.

The user interface 398 may be configured to receive input from a userand/or provide output to a user. The user interface 398 may include, forexample, a display, a keyboard, keypad, function keys, mouse, scrollingdevice, input/output ports, touch screen, or any other mechanism bywhich a user may interface with the system. Although the user interface398 is shown as being directly connected to the controller 392 andwithin the reel editor 340, the user interface 398 could alternativelybe remote from the controller 392 and/or reel editor 340. Likewise, insome embodiments, other components of the reel editor 340 could beremotely located.

The first winding station 341 of the reel editor 340 is configured toreceive a roll of printed web product (e.g., reel portion 1, 320 a). Insome embodiments, the first winding station 341 may comprise one or morewinding devices 342 that are configured to cause an installed roll ofprinted web product to unwind or wind (depending on the direction ofoperation).

The second winding station 343 of the reel editor 340 is configured toreceive a tail end of the roll of printed web product and enablegathering (e.g., winding) of the printed web product roll as the roll isunwound from the first winding station 341. For example, as the roll ofprinted web product 320 is processed through the reel editor 340, thetail end may attach to and begin the reel portion 2, 320 b. In someembodiments, the second winding station 343 may include one or morewinding devices 344 that are configured to cause an installed roll ofprinted web product to unwind or wind (depending on the direction ofoperation).

The cutting station 345 is configured to enable one or more portions ofthe roll of printed web product to be edited (e.g., removed). In thisregard, depending on the configuration of the reel editor 340, thecutting station 345 may be designed for manual interaction from anoperator (e.g., to perform the cutting) or automatic control of thecutting, or some combination of both.

In some embodiments, the cutting station 345 may include one or more cutdevices 346 that are configured to be utilized (e.g., manually or undercontrol of the controller 392) to cut one or more portions of the rollof printed web product 320.

In some embodiments, the cutting station 345 may be configured to enablecutting of the roll of printed web product in the width direction. Insuch a regard, a portion of the roll of printed web product 320 may beremoved such as between two cuts along the width direction. In someembodiments, the remaining portions of the roll of web product 320 maybe connected back together to re-form the roll of printed web product(albeit with a portion removed). In some embodiments, each portion ofthe roll of printed web product may be used to form two “child” rolls ofprinted web product. In some embodiments, such cuts along the width ofthe roll of printed web product may be used to remove waste betweenorder sections on the roll of printed web product.

In some embodiments, the cutting station 345 may be configured to enablecutting of the roll of printed web product in the length direction(e.g., slitting). In some such embodiments, a portion of the roll ofprinted web product 320 may be removed.

In some embodiments, slitting (e.g., at a slitting section) may be usedto reduce the width of the roll of printed web product to a desiredwidth such as to match a planned (e.g., scheduled) component of themanufacturing process. For example, if there are multiple lanes oforders on the roll of printed web product, one or more lanes (e.g., fromthe control plan/reel plan) could be removed to enable processingthrough other downstream equipment. For example, the printing press maybe able to print on a width of 12 feet, but a downstream component mayonly be able to handle a width of 6 feet. In such embodiments, theslitter could be used to form one or more “child” rolls of printed webproduct. In some embodiments, the control plan could be updated bygeneration of individual control plans for each child roll that wasformed.

FIG. 5A shows an example reel editor 340 with a cutting station 345. Aroll of printed web product 320 is being processed by the reel editor340. FIG. 5B shows a close up of an example cutting station 345. Anoperator 318 is performing a cut along a width of the roll of webproduct, thereby forming a first portion of the roll of printed webproduct 320 a and a second portion of the roll of printed web product320 b.

In some embodiments, the reel editor 340, such as through the controller392, is configured to edit a roll of printed web product and update acorresponding reel map to account for the editing. In this regard,updating the reel map enables efficient use of the reel map indownstream portions of the manufacturing process. In some embodiments,the controller 392 is configured to operate a reel editor module toperform example functions accordingly.

In some embodiments, the reel editor module is configured to receive areel map associated with the roll of printed web product, wherein eachroll of printed web product is associated with a unique reel map. Forexample, the reel editor module may gather the reel map from thecontroller 90 of the manufacturing process 10 (and/or from variousmodules of the manufacturing process 10). As an example, the roll ofprinted web product may have recently undergone a check from the visionsystem module (such as looking for waste or defects). In someembodiments, the reel editor module may be configured to receive thereel map from the vision system module.

The reel map, such as described herein, may comprise roll data thatincludes data corresponding to one or more printed orders on the roll ofprinted web product. The roll data may comprise waste data that includesone or more locations of waste sections on the roll of printed webproduct. In such example embodiments, each of the waste sections maycorrespond to at least one of waste on the roll of printed web productor unsatisfactory images that are printed on the roll of printed webproduct. Accordingly, the reel map may be updated, such as from thevision system module, with indications of such waste or defects.

The reel editor module may also be configured to control the firstwinding device to unwind the roll of printed web product to positionlocations of waste at the cutting station for corresponding editing. Forexample, the controller 392 may cause the roll of printed web product320 to be unwound to a position on the cutting station 345 so that anoperator may cut out the waste. Likewise, such cutting and/or removalcould be performed automatically, such as under control of thecontroller 392.

The reel editor module may also be configured to control at least one ofthe first winding device of the first winding station or a secondwinding device of the second winding station to wind the edited roll ofprinted web product after removal of the waste section. For example, thereel editor module may be configured to wind up the edited portion ofthe roll of printed web product (e.g., form reel portion 2 320 b in FIG.4).

In some embodiments, the reel editor module may be configured to updatethe reel map associated with the roll of printed web product by updatingthe roll data based on the removed waste sections to form an updatedreel map associated with the edited roll of printed web product. Forexample, the reel editor module may be configured to update the overalllength of the printed web product on the edited roll. As anotherexample, the reel editor module may be configured to update the reel mapwith the revised length for each order section and/or the revised numberof remaining structures in each order section. In some embodiments, suchas during creation of one or more “child” rolls, the reel editor modulemay be configured to develop/form corresponding reel maps for the“child” rolls.

In some embodiments, the reel editor module may be configured to controlat least one of the first winding devices 342 or the second windingdevices 344 to rewind the now edited roll of printed web product. Inthis regard, when the roll of printed web product is first unwound toaccomplish editing, the direction of the winding when at the secondwinding station 343 (e.g., reel portion 2) is backwards. Thus, the reeleditor module may rewind the roll of printed web product, such as backto the first winding station 341, to put the order of winding back inthe proper direction.

In some embodiments, the reel editor module may be configured to count,detect, and/or process the roll of printed web product as it is rewound.Depending on the configuration of the roll of printed web product and/orcomponents of the reel editor, various detection techniques could beused. For example, markings may be read to enable such detection.Additionally or alternatively, overall length could be determined, suchas by knowing the speed of rotation of the winding device(s) and thetime of operation to complete the rewind. These are just some examplesof how to determine characteristics regarding the roll of printed webproduct, as others are contemplated by various embodiments of thepresent invention. In this regard, various specifics regarding the nowedited roll of printed web product can be determined. For example, theoverall length of the roll, various order sizes, etc., may bedetermined. This enables accurate updating of the reel map, as unknownediting may occur at the reel editor (e.g., an operator may visually andmanually determine extra waste to remove—such as above and beyond theindicated waste on the reel map prior to editing).

In some embodiments, the reel editor module is configured to provide theupdated reel map to one or more modules of the manufacturing process 10(e.g., a corrugator for further processing of the now edited roll ofprinted web product).

In some embodiments, the reel editor module is configured to cause oneor more labels for the edited roll of printed web product to be printedand/or applied to the edited roll of printed web product. The label mayinclude, for example, identification of the edited roll of printed webproduct. Additionally, the label may indicate one or morecharacteristics about the edited roll, such as the new overall weblength, the web width, orders information, among many other things.

As noted above, the reel editor may be a separate component of themanufacturing process 10. Alternatively, some or all of the reel editormay be incorporated into at least some components of the manufacturingprocess 10. For example, the reel editor may be a part of the printingpress and/or the component for product processing/formation. In eithercase, there may, in some situations, be extra waste created by editingthe roll at the printing press or other components. For example, editinga roll of printed web product at a corrugator may result in excess wastedue to running the corrugator while editing occurs. In this regard, asdescribed in greater detail herein, the corrugator uses multiple rollsof web product to form a finished layered corrugated board web. If thetop liner is being edited, then the other rolls may be runningneedlessly, creating unnecessary waste (and cost).

In some embodiments, the reel editor module (or anothermodule/controller of the manufacturing process 10) may be configured todetermine whether or not to edit waste from a roll of printed webproduct. In this regard, there may be one or more reasons to not edit aroll of printed web product even if there is some waste on the roll. Forexample, it may be important to finish one or more orders on the rollwithin a certain time period (e.g., the order is due), and the operator(and/or reel editor module) may determine that the extra time spentremoving the waste is not worthwhile. Along similar lines, the cost ofrunning the reel editor to edit the roll may be greater than the cost ofprocessing the roll of printed web product with the defects/waste.Further, such determinations may vary depending on many factors, such asdesired quality of the images, customer requirements, different pricepoints, among other possible factors.

In this regard, in some embodiments, the reel editor module may beconfigured to receive, such as from a vision system module of amanufacturing process, a reel map associated with the roll of printedweb product. As noted herein, each roll of printed web product isassociated with a unique reel map. The reel map may comprise roll datathat includes order data and waste data. The waste data may indicate oneor more waste sections on the roll of printed web product, wherein eachof the one or more waste sections corresponds to at least one of wasteon the roll of printed web product or unsatisfactory images that areprinted on the roll of printed web product. The order data maycorrespond to one or more printed orders on the roll of printed webproduct and include at least one of cost associated with processingmaterial for the order, customer data associated with the roll ofprinted web product, desired quality data associated with the roll ofprinted web product, or pricing data associated with the roll of printedweb product.

In some embodiments, the reel editor module may be configured to utilizedata from the reel map to determine an amount of waste on the roll ofprinted web product. For example, the reel editor module may utilize thewaste data from the reel map to determine an overall length reduction inthe roll if the roll was edited—e.g., corresponding to the amount ofwaste on the roll. Additionally or alternatively, the amount of wastemay be determined based on a number of factors, such as each ordersection, on certain (e.g., important) order sections, only defectedimages, etc.

In some embodiments, the reel editor module may be configured todetermine a waste tolerance threshold for the roll of printed webproduct. For example, the reel editor module may take into account anumber of factors to form a waste tolerance threshold, such as the costof running various components of the manufacturing process, the cost ofmaterials of the manufacturing process, customer preferences, desiredquality data associated with the roll of printed web product, or pricingdata associated with the roll of printed web product. Based on these orother factors and possible weights associated with the factors, a wastethreshold may be determined.

In some embodiments, the reel editor module may be configured todetermine if the determined amount of waste satisfies the wastetolerance threshold. In an instance in which it does satisfy the wastetolerance threshold, then the reel editor module (or othermodule/controller in the manufacturing process 10) may determine not toedit the roll of printed web product. In an instance in which it doesnot satisfy the waste tolerance threshold, then the reel editor modulemay determine the need to edit the roll of printed web product.

In response, the reel editor module may be configured to provide anindication or instruction according to its determination. For example,the reel editor module may provide a message, notification, or otherindication to an operator to indicate whether or not the roll of printedweb product should be edited. In some embodiments, the reel editormodule may cause the roll of printed web product to be sent to and/orprocessed by the corresponding component based on its determination(e.g., sent to the reel editor or sent to the corrugator).

In some embodiments, the determination of whether the amount of wastesatisfies the waste tolerance threshold may be based on certain rules.For example, the comparison may be made at each order section. In suchan example embodiment, the reel editor module may make the determinationat various levels. For example, in some embodiments, all of the ordersections may have to satisfy the waste tolerance threshold to not havethe roll edited. In another example, the order sections may be weighteddue to various factors (such as described above) and only certain ordersections may need to satisfy the waste tolerance threshold in order forthe roll to not be edited. Similarly, in some embodiments, only acertain number of order sections may need to satisfy the waste tolerancethreshold in order for the roll not be edited.

In some embodiments, the reel editor module may determine the costassociated with running the reel editor to remove the determined amountof waste. For example, the reel editor module may factor in labor costsassociated with running the reel editor to remove the waste.

In some embodiments, the reel editor module may determine the costassociated with running the processing/formation component (e.g., acorrugator) with the waste. For example, there may be costs associatedwith extra material being run through the corrugator. Additionally,there may be labor costs associated with dealing with the waste duringor after use of the corrugator.

In some such embodiments, the reel editor module may be configured tocompare the determined costs associated with running the reel editor vs.the cost associated with running the processing/formation component withthe waste and determine which cost is less. Then, based on which willcost less, the reel editor module may determine whether or not the rollof printed web product should be edited (such as by determining that itshould be edited if the cost of running the reel editor is less thanrunning the corrugator with the waste). Such embodiments may be usedinstead of the waste threshold test and/or in conjunction with the wastethreshold test. For example, the cost comparison could be part of thedetermination of the waste tolerance threshold (as there may be atipping point when the amount of waste may cause the cost comparison tomove from a determination of no need to edit the roll to a determinationof a need to edit the roll).

In some embodiments, one or more of the determinations by the reeleditor module may be sent to the customer insights database to provideupdated information that may be useful for the customer and/ormanufacturer.

Example Corrugated Box Manufacturing Process

Corrugated sheet and box manufacturing is an example paper, sheet,and/or box manufacturing system. In some such manufacturing, acorrugator is used to glue together layers of board web with a flutemedium positioned in between. Depending on the desired characteristicsof the corrugate board web, different layers/arrangements can becombined. Once formed, the corrugate board web (e.g., top layer, flutemedium, and bottom layer) may then be cut into appropriate sheet or boxstructures, and later scored, cut, glued etc. to form the broken downbox (that is then folded and manipulated to form the box, such as by thecustomer). Although the following description provides detailed examplesof “corrugators”, some example embodiments of the present inventioncontemplate the term “corrugator” to mean a board-making device, such asa high speed laminator.

FIG. 6A illustrates an example corrugated box manufacturing process 510according to various embodiments of the present invention. Themanufacturing process 510 includes a number of phases that result in afinished corrugated sheet or box that is shaped and printed per thecustomer's order. The process 510 may include an ordering phase 512, aplanning phase 514, a print phase 530, a reel editor phase 540, a boardmaking/cutting phase 560 (e.g., a sheet formation/processing phase), afinishing phase 570, and a tracking/logistics phase 580. In someembodiments, less or more phases or different orders of phases arecontemplated. Additionally, while the described example is detailed forcorrugated box making, some embodiments of the present invention arecontemplated for extension into other product manufacturing, includingprinted paper-based product manufacturing, such as folded carton,beverage labels, flexible paper, industrial bags, plates, cups, décor,and many others.

In the ordering phase 512, a customer may supply an order that includesdesired characteristics for the end product. For example, the customermay provide a number of desired sheet or box structures, sheet or boxshape requirements, one or more images/designs for printing on the sheetor box, color specifications, among many others. In some embodiments,the customer 512 may input such an order through a web interface. Theweb interface may enable the customer 512 to easily input the desiredcharacteristics of the order electronically. The web interface may alsoenable the customer to perform many related tasks, including, forexample, updating orders, tracking orders, handling payment, requestingassistance, setting up automated ordering (e.g., recurring ordering),viewing and approving example images (“soft proofing”), viewing exampleend products, etc.

In addition to providing increased efficiency of process for thecustomer, the web interface may also directly interact with and provideinformation for automated processes useful in the remainder of themanufacturing process 510. For example, the information from the webinterface may be fed directly into a corrugator plan controller (such asthe controller 590) and utilized accordingly. For example, as describedherein, the information from the web interface may be used to form acorrugator plan and/or associated reel map or print plan of thecorrugated sheet or box structure making process. Additionally, however,the information from the web interface may be used to provide on-the-flyupdates or adjustments to the manufacturing process. Further, feedback(e.g., from the controller 590) may be provided back to the webinterface for the customer, such as tracking information, images of thecompleted sheet or box structures, among other things.

In some embodiments, a controller 590 may be configured to performvarious functionality useful in the manufacturing process 510 (e.g., thevarious modules/phases described herein). For example, the controller590 (such as during the planning phase 514) may be configured to form acorrugator plan (which may be included in an associated reel map), suchas may be used in conjunction with the corrugator 550 (e.g., during theboard making phase/cutting phase 560). As used herein, in someembodiments, an associated reel map may be an example of a corrugatorplan. In this regard, other example corrugator plans (e.g., a printplan) can be used, formed, etc. Additionally or alternatively, thecontroller 590 may be configured to form a print plan that is used inthe printing phase 530 (such as described herein). Likewise, thecontroller 590 may be used with the ordering phase 512, such as toreceive order information, the finishing phase 570, and/or thetracking/logistics phase 580. An example controller 590 is describedfurther herein as controller 690 (which is shown and described withrespect to FIGS. 7A and 7B). In some embodiments, the controller 590 maybe spread over any number of controllers at any of the various phases ofthe manufacturing process 510.

In some embodiments, sections of the process flow can be shifted fromplant to plant or device to device due to various externalcircumstances. For example, repair of certain parts of the corrugator,replacing certain printer inks, etc., may cause only certain customersheet or box structures to be able to be manufactured. In this regard,in some embodiments, certain portions of the process flow may beshifted, such as being jumped in line, moved to another facility, etc.,in order to maintain efficient up time of operation of the printer(s)and corrugator(s).

The manufacturing process 510 may also include the printing phase 530,reel editor phase 540, and board making/cutting phase 560. In someembodiments, the printing phase 530, reel editor phase 540, and boardmaking/cutting phase 560 may be performed using a corrugator 550 (suchas shown in FIG. 6A) or other manufacturing system. Alternatively, insome embodiments the printing phase 530 and/or reel editor phase 540 maybe performed separately, prior to the corrugator 550′ (such as shown inthe manufacturing process 510′ shown in FIG. 6B). Similarly, FIG. 6Aalso illustrates that the real editor phase 540 may be optional within acorrugator 550 that also employs a printing phase 530. FIG. 7Aillustrates an example corrugator 650 that incorporates the printingphase 530, the reel editor phase 540, and the board making/cutting phase560 to form an in-line process. In some embodiments, the reel editorphase 640 may not be included in the example corrugator 650 of FIG. 7A.FIG. 7B illustrates an example corrugator 650′ with the printing phase530 and the reel editor phase 540 occurring separately, prior to theboard making/cutting phase 560. This approach is sometimes referred toas a near-line process.

With reference to FIG. 7A, the corrugator 650 may, such as throughcontroller 690, cause conveyance of one or more paper web, printed web,corrugated board web, and/or flute medium through the machine (andvarious phases), such as along the machine direction (MD) arrow. Forexample, one or more conveyor means (e.g., a conveyor belt) and/ormotors may be used to cause a top layer 622 of paper web to pass througha printing phase 630 and, optionally, a reel editor phase 640. The toplayer 622 of paper web may be held in a roll 621 (or other form), suchas may be referred to herein as a roll of web product. The corrugator650 may also control introduction of one or more flute mediums 629and/or other layers to form the corrugated board web (such as the roll623 of the bottom layer 624 of corrugated board web).

As described herein, in some embodiments, a reel map (e.g., acorrugator/control plan) may be used to help maintain efficientoperation of the corrugator and avoid waste during making of the sheetor box structures. In this regard, a certain arrangement of sheet or boxstructures may need to be followed through the corrugator 650. Suchoperation and tracking may occur, such as through use of the controller690.

As described in more detail herein, the controller 690 provides logicand control functionality used during operation of the corrugator 650and, in some embodiments, the entire manufacturing process 510. In someembodiments, the functionality of the controller 690 may be distributedto several controllers that each provides more limited functionality todiscrete portions of the operation of manufacturing process 510. In thisregard, the controller 690 may have the same or similar suitablehardware or software to the controller 90 described herein.

The controller 690 may be operably coupled with one or more componentsof the manufacturing process 510, including for example, the roll 621 ofthe top layer 622 of corrugated board web, a medium holder (e.g., roll)628 of medium 629, the roll 623 of the bottom layer 624 of corrugatedboard web, various components of the printing phase 630, variouscomponents of the reel editor phase 640, various components of theboarding making phase 645, various components of the cutting phase 660,conveyance means of the corrugator, various components of phases for themanufacturing process, and other components (such as described herein).For example, depending on the components, the controller 690 may beoperably coupled such as through use of solid-core wiring, twisted pairwiring, coaxial cable, fiber optic cable, mechanical, wireless, radio,infrared, etc. In this regard, depending on the components, the operablecoupling may be through one or more intermediate controllers ormechanical coupling, such as used for controlling some components (e.g.,controlling operation and/or feeding of the roll 621 of the corrugatedboard web). In some embodiments, the controller 690 may be configured toprovide one or more operating signals to these components and to receivedata from these components.

As noted above, the controller 690 (e.g., the corrugator plancontroller) may be split into more than one controller, such as multiplecontrollers that exchange information, data, instructions, etc. Forexample, the controller 690 may be split into a corrugator planningsoftware controller, a corrugator machine user interface controller, acorrugator system controls, press 630 operations and graphics workflowsoftware and/or specific functional controls (e.g., a separate visionsystem such as described herein).

In some embodiments, such as described in greater detail herein, thecontroller 690 may be operably coupled to one or more vision systems,such as for detecting markers and/or defects/errors during themanufacturing process. Depending on the feedback from the visionsystems, the controller 690 may control the corrugator 650 and/ormanufacturing process 510 accordingly.

Depending on the configuration of the corrugator, the printing phase 630may occur prior to combining the layers of corrugated board web 621, 623and flute medium 628 (e.g., “pre-print”) or after combining two or morelayers (e.g., “post-print”). In some embodiments, printing may occur toother layers (e.g., the bottom layer 623), such as in alternative to orin addition to the top layer 621.

During the printing phase 630, the controller 690 may direct the pressdigital front end (DFE) and raster image processor (RIP), etc., to printone or more images at specific locations on the top layer 622 of thepaper web. Depending on the configuration of the corrugator 650 and/ormanufacturing process 510, the controller 690 may utilize a process flow(e.g., reel map) to determine where on the paper web to print the imagesand/or markers. For example, an image selected by the customer (such asa bottle), may be printed in the center (or other section) of a sheet orbox structure—such as may ultimately be visible for marketing or otherpurposes once the box is formed. Any image (including, words, markers,instructions, etc.) are contemplated by various embodiments of thepresent invention. Example markers that can be printed, include anymarker that may be used by various components of the manufacturingprocess 510, such as for tracking, cutting, printing, etc. Furtherdescription regarding possible markers and their utilization is providedin greater detail herein. In this regard, the controller 690 may beconnected to one or more vision systems that are used to read or detectcolor, defects, and various markers for controlling and/or updatingoperation of the corrugator 650.

During the reel editor phase 640, the controller 690 may be configuredto perform functions described herein related to editing or determiningwhether to edit the printed top layer of board web. Although shownin-line, in some example embodiments, the reel editor 640 may be out ofline or near-line such that the roll of web product may be transferredto the reel editor 640 for processing. In some embodiments, thecorrugator may have one or more functions/features that enable editingof the roll of web product (such as removing waste). In some suchexample embodiments, the reel editor 640 may form part of thecorrugator.

During the board making phase 645, the controller 690 may be configuredto cause combining of one or more layers and/or flute medium to form thecorrugated board web for the boxes. For example, the controller 690 maybe configured to cause fluted medium 629 to be fed into contact with oneor more layers of corrugated board web, such as between a top layer 622(such as from the roll 621) and a bottom layer 624 (such as from theroll 623). In this regard, in some embodiments, the fluted medium 629may be fed into contact with the top layer 622 prior to the combinedfluted medium 629 and top layer 622 coming into contact with the bottomlayer 624. The controller 690 may cause formation of the combined layersinto a layered corrugated board web 620, such as through use of glue orother adhesive.

During a corrugator editing phase 649, the controller 690 may beconfigured to edit the corrugated board web, such as by chopping outwaste or undesirable corrugated board web. Such waste can be removedfrom the corrugator 650.

During the cutting phase 660, the controller 690 may be configured tocut out the sheet or box structures. In this regard, the controller 690may be operably coupled to the various knives to control operationduring the cutting phase 660. In some embodiments, the controller 690may be configured to utilize the process flow (e.g., reel map) todetermine how to operate the various knives (e.g., move the knives,cause a cut to occur, etc.).

FIG. 8 shows an example cutting phase 660 that includes a knife (e.g.,slitter 664) that is configured to cut the layered corrugated board web620 in the longitudinal (or machine) direction. The cutting phase 660also includes two knives 666, 667 that are each configured to cut thelayered corrugated board web 620 in the lateral direction or crossdirection CD. As described herein, the controller 690 may be operablycoupled to the various knives to control operation thereof. In someembodiments, the controller 690 may be configured to utilize the processflow (e.g., reel map) to determine how to operate the various knives(e.g., move the knives, cause a cut to occur, etc.).

As the layered corrugated board web 620 passes through the cuttingphase, a slitter 664 may be configured to split the layered corrugatedboard web 620 to cause it to split into different sections that travelon different paths (such as the top section 626 that travels along thetop path and the bottom section 627 that travels along the bottom path).In some embodiments, a first sheet or box structure may form the topsection 626 and a second sheet or box structure may form the bottomsection 627—thereby creating two different paths that separate the twotypes of sheet or box structures (e.g., sheet or box structure A, 691 isformed in the top section 626 and sheet or box structure B, 692 isformed in the bottom section 627). The location 665 in which the slitter664 performs the cut is important because sheet or box structures mayvary as the layered corrugated board web 620 travels through thecorrugator. For example, FIG. 3A shows that a slitter would need to cutat a first position P₁ to cause separation of the sheet or boxstructures A, 691 from the sheet or box structures B, 692. However, theslitter would need move at the right time (e.g., the transition from thesheet or box structures A, B to the sheet or box structures C, D) or asecond slitter may be used to cut instead at the second position P2 tocause separation of the sheet or box structures C, 693 from the sheet orbox structures D, 694. Referring back to FIG. 8, the slitter 664 may bemovable (such as based on instruction from the controller 690) in thecross direction CD in order to cut the layered corrugated board web 620at the proper position.

Once separated into different paths, the various sections of layeredcorrugated board web 626, 627 may pass through respective knives 666,667. In some embodiments, the knives 666, 667 may be configured (such asbased on instruction from the controller 690) to cut the sheet or boxstructures in the lateral (cross) direction in order to form the desiredsheet or box structures. For example, knife 666 cut the top section 626to form the sheet or box structures A, 696. Likewise, knife 667 cut thebottom section 627 to form the sheet or box structures B, 697.

In some embodiments, other knives may be utilized for cuts, such as sideslitters for cutting scrap along the edges. Likewise, other componentsmay be utilized, such as scorers for pre-creasing sheet or boxstructures. Such other knives and/or components may be formed as part ofthe above described systems.

Referring back to FIG. 6A, with the sheet or box structures cut, themanufacturing process 510 may continue to the finishing phase 570. Thefinishing phase 570 may include additional printing, additional cutting,additional gluing, and/or other necessary functions to achieve afinished sheet or box structure for sending to the customer. In someembodiments, a vision system or other visual inspection system may beused to confirm accuracy of the order.

The manufacturing process 510 may also include a tracking/logisticsphase 580 that includes tracking the finished sheet or box structuresand preparing/delivering them to the customer. In some embodiments, oneor more tracking or counting systems can be implemented upstream in themanufacturing process 510, such as to enable tracking/logistic planning(including separating orders) throughout the manufacturing process 510.

Example Color Marking System

In some embodiments, the present invention contemplates using a colormarking system to enable automated efficient control of variousmanufacturing systems, such as a reel editor. Though the followingdescription focuses on control of a corrugator, some embodiments of thepresent invention contemplate using the proposed color marking scheme(or aspects thereof) for automated control of any of the contemplatedmanufacturing systems, such as a reel editor. In some embodiments, otherschemes may be employed, such as include computer readable markersand/or non-computer readable markers.

In some embodiments, the color marking scheme may be employed instead ofa readable marker. In addition to overcoming some of the prior manualchecking shortcomings described above, the contemplated color markingsalso provide advantages over prior three line black-only cut-to-markmarkers. In this regard, some corrugators detect such cut-to-markmarkers and immediately initiate a cut. This approach, however, islimited—as all the cut markers look the same and, thus, the reel map hasto be monitored closely and continually and manually checked to confirmthat the right boxes were being cut/printed.

The present invention contemplates using a similar three line mark, bututilizing different colors to portray an upcoming “change” to thecorrugator. In particular, a vision system reads the color of eachmarker. When a different color is recognized, then the controller knowsto “check” the corrugator plan and/or associated reel map to determinehow to operate. For example, the reel map may tell the corrugator that adifferent position of the knife is needed, different slitting is needed,new scoring is needed, etc. In some embodiments, the colors could beused to locate a position on the corrugator plan and/or associated reelmap, making identification of where along the reel map the corrugator iseasier. Further, such a system is simpler than using a readable marker,as it utilizes the already formed corrugator plan and/or associated reelmap. In particular, it may simply trigger an automatic checking of thecorrugator plan and/or associated reel map at the appropriate time (suchas opposed to having to manually watch and manually check the reel map).

Along these lines, another benefit of some embodiments of the proposedcolor marking system is the leveraging of traditional three-linecut-to-mark markers. FIG. 9 shows an example layered corrugate board web420 that includes traditional three-line cut-to-mark markers 430. Whenthe cut-to-mark markers 430 are detected, the knife will initiate a cut,such as along line 440 to separate the box or sheet structure 491. Inthe present invention, some embodiments utilize the three-line marker,but use a change in color to add the ability for the controller (e.g.,controller 90) to detect a change and, thus, consult the corrugator planand/or associated reel map for details regarding the anticipated changein operation.

FIG. 10 illustrates an example color marking system. In the depictedembodiment, a layered corrugate board web 420 includes three differentsheet or box structures—sheet or box structure A, 491; sheet or boxstructure B, 492; and sheet or box structure C, 493. As the layeredcorrugated board web 420 passes along the machine direction (MD), one ormore detectors (e.g., detectors 410 a, 410 b) detect a color markerand/or whether a color change has occurred.

For example, upon detecting color marker 430 (black), the detector 410 amay inform the controller 490 which may, in response, cause a cut tooccur (e.g., along line 440 a). In some embodiments, knowing where alongin the reel map the layered corrugate board web is, the controller 490may know how to operate, such as anticipating an upcoming cut a distanceW₁ away. In such an example embodiment, the controller 490 may wait toread the next color marker 430 and then initiate a cut in responsethereto or the controller 490 may simply monitor the distance andinitiate a cut once the distance W₁ has passed.

As the layered corrugated board web 420 continues to pass along themachine direction (MD), the corrugator continues to apply cuts at adistance W1 between each cut—causing cuts along 440 b, 440 c, and 440 d.However, when the one or more of the detectors 410 a, 410 b detect achange in color, such as when detecting color marker 432 (teal), thecontroller 490 may, in response (e.g., be triggered to), check the reelmap and determine how to operate. For example, the controller 490 mayknow that the new distance between cuts is W₂. This would result in cutsalong lines 440 e, 440 f, 440 g, and 440 h—until another change in colorwas detected by detecting color marker 434 (magenta). In response, thereel map could be checked and it could be determined that a new distancebetween cuts is W₃.

In the above example, the determination of when a color change occurstriggers automatic checking of the corrugator plan and/or associatedreel map, which then informs the controller 490 how to operate thecorrugator. In this regard, the checking of the corrugator plan and/orassociated reel map is automated (instead of manual) and performed onlywhen needed—e.g., when a change to a new sheet or box structure occurs.

In some embodiments, the color information of the detected color markeris provided by the one or more detectors to the controller 490. In suchexamples, the controller 490 may be configured to compare the detectedcolor to a prior color to determine if a sufficient degree of colorchange has occurred in order to trigger looking up the corrugator planand/or associated reel map. For example, the amount of change in colormay be compared to a color change threshold to see if a sufficientamount of color has changed.

In some embodiments, the colors are designed to be formed from digitalprint standards for 4 color Cyan/Magenta/Yellow/Black (CMYK) andextended gamut Orange/Violet/Green (OVG) plus custom colors as desiredand uniquely recognizable by detection technology. Such exampleembodiments may advantageously limit ink utilization and simplifyprintability. In some embodiments, RGB print standard approach could beused. In some embodiments, the color of the substrate being used may beaccounted for. For example, yellow and orange and/or light to browncolors could be skipped on white top or brown kraft paper products.

Though the depicted embodiment shows the color marker positioned withina sheet or box structure, in some embodiments, the color marker may bepositioned in the margins or other waste area, but still associated withthe corresponding sheet or box structure.

As detailed herein, some embodiments of the present inventioncontemplate various locations for detectors, such as for detecting thecolor of color markers. For example, FIG. 9 shows two separate detectors410 a, 410 b positioned near each edge of the layered corrugated boardweb 420. In other embodiments, one or more detectors may cover anyamount up to and including the entire cross direction of the layeredcorrugated board web. For example, FIG. 11 shows such an exampledetector 410. With such an example detector 410, the detector 410 isable to detect a color marker that is at any point along the crossdirection.

FIG. 11 illustrates an example system that uses detected change in colorto determine where to position the slitter to transition betweendifferent sheet or box structures in a side-by-side running of sheet orbox structures. For example, the controller 490 may be operating withthe slitter at a position to initiate a longitudinal (machine) directioncut along line 460 a while reading color markers 430 (black). However,upon the detector 410 detecting the change in color to color marker 432(cyan), the controller 490 may check the reel map and update theposition of the slitter to initiate a cut along line 460 b. Likewise,the controller 490 may change the position of the slitter to cut alongline 460 c after checking the reel map in response to detecting a changein color to the color marker 436 (green).

Notably, FIG. 11 also illustrates an example where the slitter positionstays the same such that two sections of sheet or box structures aremade (e.g., sheet or box structures B and D), but sheet or box structureB transitions to sheet or box structure C on the top section. In thisregard, the detector detects a change in color when detecting colormarker 434. In response, the reel map is checked and there is no changein operation to either the slitter or the knife for the bottom section(e.g., the bottom section is still sheet or box structure D). However,the knife for the top section changes when it initiates a cut from adistance between cuts of W₄ to a distance between cuts of W₅—therebyadjusting to sheet or box structure C.

In some embodiments, readable markers may still be present on, at least,some of the sheet or box structures. Such readable markers (e.g., barcodes, QR codes, etc.) may, in some embodiments, be configured to enabletracking of the orders. Additionally or alternatively, the readablemarkers may supplement the color markers and enable some control of thecorrugator upon being read and/or may be utilized for downstreamprocesses after the corrugator (e.g., for tracking and other logistics).FIG. 12 illustrates an example layered corrugate board web 420 withsheet or box structures A, 491 that have color markers 430 and readablemarkers 470.

Example Other Product Manufacturing Processes

As noted herein, some embodiments contemplate systems for controllingmanufacturing of various products, such as various paper-based products,including corrugated boxes, folded carton, labels, flexible paper,industrial bags, plates, cups, décor, and many others. FIGS. 13-16illustrate block diagrams of various example other paper-based productmanufacturing contemplated by various embodiments described herein. Inthis regard, some embodiments of the present invention contemplate oneor more controllers (e.g., controller 90) that can generate and providea control plan to various devices/systems for performing efficientmanufacturing of such various products.

FIG. 13 shows a block diagram of an example folded carton manufacturingprocess according to various embodiments of the present invention. Themanufacturing process 710 includes a number of phases that result in afinished folded carton that is shaped, formed, and printed per thecustomer's order. The process 710 may include an ordering phase 712, aplanning phase 714, a print phase 730, a reel editor phase 740, a sheetformation/processing phase 760, a finishing phase 770, and atracking/logistics phase 780. Such phases may be similar to the phasesdescribed with respect to the manufacturing phase 10 of FIG. 1. In someembodiments, less or more phases or different orders of phases arecontemplated. Depending on the desired configuration, one or morecontroller(s) 790 may be used to control one or more various phases(e.g., various systems/devices therein) of the manufacturing process710. In some embodiments, one device/system may encompass multiplephases, such as two or more of the printing phase 730, the reel editorphase 740, the sheet formation/processing phase 760, and the finishingphase 770.

In some embodiments, like the manufacturing process 10 described withrespect to FIG. 1, the example folded carton manufacturing process 710may include one or more cutting devices 765 for cutting one or moresheets (or structures) from the roll of web product. Additionally, insome embodiments, a web forming device may form an updated web, such asprior to processing through the cutting device.

In some embodiments, the folded carton manufacturing process 710 mayinclude one or more unique devices, such as a folding/gluing device 775that may form part of the finishing phase 770 (or the sheetformation/processing phase 760). The folding/gluing device 775, such asusing one or more folding arms or other hardware and/or varioussoftware, may be configured to perform one or more folds of varioussheets to form the desired folded carton. In some embodiments, thefolding device 775 may be configured to apply glue separately or inaddition to performing the one or more folds.

FIG. 14 shows a block diagram of an example industrial bag manufacturingprocess. The manufacturing process 810 includes a number of phases thatresult in a finished industrial bag that is shaped, formed, and printedper the customer's order. The process 810 may include an ordering phase812, a planning phase 814, a print phase 830, a reel editor phase 840, asheet formation/processing phase 860, a finishing phase 870, and atracking/logistics phase 880. Such phases may be similar to the phasesdescribed with respect to the manufacturing phase 10 of FIG. 1. In someembodiments, less or more phases or different orders of phases arecontemplated. Depending on the desired configuration, one or morecontroller(s) 890 may be used to control one or more various phases(e.g., various systems/devices therein) of the manufacturing process810. In some embodiments, one device/system may encompass multiplephases, such as two or more of the printing phase 830, the reel editorphase 840, the sheet formation/processing phase 860, and the finishingphase 870. For example, an industrial bag manufacturing machine 850 mayencompass both the sheet formation/processing phase 860 and thefinishing phase 870.

In some embodiments, like the manufacturing process 10 described withrespect to FIG. 1, the example industrial bag manufacturing process 810may include one or more cutting devices 865 for cutting one or moresheets (or structures) from the roll of web product. Additionally, insome embodiments, a web forming device may form an updated web, such asprior to processing through the cutting device.

In some embodiments, the industrial bag manufacturing process 810 mayinclude one or more unique devices, such as a tuber device 872 and/orbottom device 874 that may form part of the finishing phase 870 (or thesheet formation/processing phase 860). The tuber device 872, such asusing various hardware and/or software, may be configured to form one ormore sheets into one or more tubes. The bottom device 874, such as usingvarious hardware and/or software, may be configured to form a bottom oneach of the tubes to form the industrial bag.

FIG. 15 shows a block diagram of an example cup manufacturing process.The manufacturing process 910 includes a number of phases that result ina finished cup that is shaped, formed, and printed per the customer'sorder. The process 910 may include an ordering phase 912, a planningphase 914, a print phase 930, a reel editor phase 940, a sheetformation/processing phase 960, a finishing phase 970, and atracking/logistics phase 980. Such phases may be similar to the phasesdescribed with respect to the manufacturing phase 10 of FIG. 1. In someembodiments, less or more phases or different orders of phases arecontemplated. Depending on the desired configuration, one or morecontroller(s) 990 may be used to control one or more various phases(e.g., various systems/devices therein) of the manufacturing process910. In some embodiments, one device/system may encompass multiplephases, such as two or more of the printing phase 930, the reel editorphase 940, the sheet formation/processing phase 960, and the finishingphase 970. For example, a cup manufacturing machine 950 may encompassboth the sheet formation/processing phase 960 and the finishing phase970.

In some embodiments, like the manufacturing process 10 described withrespect to FIG. 1, the example cup manufacturing process 910 may includeone or more cutting devices 965 for cutting one or more sheets (orstructures) from the roll of web product. Additionally, in someembodiments, a web forming device may form an updated web, such as priorto processing through the cutting device.

In some embodiments, the cup manufacturing process 910 may include oneor more unique devices, such as a cup former 977 that may form part ofthe finishing phase 970 (or the sheet formation/processing phase 960).The cup former 977, such as using various hardware and/or software, maybe configured to form one or more sheets (or structures) into a cup witha desired shape (e.g., the cup former 977 may employ a die-cutter thatcuts the sheet into a desired shape and a cup formation device thatforms the cylindrical cup shape with a bottom and glues the cuptogether).

FIG. 16 shows a block diagram of an example paper plate manufacturingprocess. The manufacturing process 1010 includes a number of phases thatresult in a finished paper plate that is shaped, formed, and printed perthe customer's order. The process 1010 may include an ordering phase1012, a planning phase 1014, a print phase 1030, a reel editor phase1040, a sheet formation/processing phase 1060, a finishing phase 1070,and a tracking/logistics phase 1080. Such phases may be similar to thephases described with respect to the manufacturing phase 10 of FIG. 1.In some embodiments, less or more phases or different orders of phasesare contemplated. Depending on the desired configuration, one or morecontroller(s) 1090 may be used to control one or more various phases(e.g., various systems/devices therein) of the manufacturing process1010. In some embodiments, one device/system may encompass multiplephases, such as two or more of the printing phase 1030, the reel editorphase 1040, the sheet formation/processing phase 1060, and the finishingphase 1070. For example, a plate manufacturing machine 1050 mayencompass both the sheet formation/processing phase 1060 and thefinishing phase 1070.

In some embodiments, like the manufacturing process 10 described withrespect to FIG. 1, the example paper plate manufacturing process 1010may include one or more cutting devices 1065 for cutting one or moresheets (or structures) from the roll of web product. Additionally, insome embodiments, a web forming device may form an updated web, such asprior to processing through the cutting device.

In some embodiments, the paper plate manufacturing process 1010 mayinclude one or more unique devices, such as a plate former 1078 that mayform part of the finishing phase 1070 (or the sheet formation/processingphase 1060). The plate former 1078, such as using various hardwareand/or software, may be configured to form one or more sheets (orstructures) into a plate with a desired shape (e.g., the plate former1078 may have a stamping device that stamps the sheet into a desiredshape).

Although the above description notes one or more distinctions betweenthe various manufacturing processes 710, 810, 910, 1010 and themanufacturing process 10, other distinctions are contemplated by someembodiments of the present invention. For example, thetracking/logistics phase for each manufacturing process may be differentor employ different techniques that allow for efficient manufacturing ofthe end product. Whether the same or different, varioustracking/marking/detecting techniques described herein may be employedwith manufacturing of such example products to provide for an efficientmanufacturing process.

Example Flowchart(s)

Embodiments of the present invention provide methods, apparatuses andcomputer program products for controlling and operating a reel editorfor manufacturing paper, sheet, or box structures according to variousembodiments described herein. Various examples of the operationsperformed in accordance with embodiments of the present invention willnow be provided with reference to FIGS. 17-18.

FIG. 17 illustrates a flowchart according to an example method forediting a roll of printed web product according to an exampleembodiment. The operations illustrated in and described with respect toFIG. 17 may, for example, be performed by, with the assistance of,and/or under the control of one or more of the controller 90, 392, 490,590, 790, 890, 990, 1090 components of the phases in the describedmanufacturing process 10, 510, 710, 810, 910, 1010 and/or modulespresent in the described platform 100.

The method 1100 may include receiving (or retrieving) a reel mapassociated with a roll of printed web product at operation 1102. Atoperation 1104, the method comprises determining one or more location ofwaste on the roll of printed web product. Then, the method comprises, atoperation 1106, unwinding the roll of printed web product to present oneor more locations associated with waste at a cutting station. Atoperation 1108, the method comprises removing the waste and winding theedited roll of printed web product. At operation 1110, the methodcomprises rewinding the edited roll of printed web product. At operation1112, the method comprises updating the reel map associated with theroll of printed web product to account for the removed waste.

FIG. 18 illustrates a flowchart according to another example method fordetermining whether or not to edit a roll of printed web productaccording to an example embodiment. The operations illustrated in anddescribed with respect to FIG. 18 may, for example, be performed by,with the assistance of, and/or under the control of one or more of thecontroller 90, 392, 490, 590, 790, 890, 990, 1090 components of thephases in the described manufacturing process 10, 510, 710, 810, 910,1010 and/or modules present in the described platform 100.

The method 1200 may include receiving or retrieving a reel mapassociated with a roll of printed web product at operation 1202. Atoperation 1204, the method comprises determining an amount of waste onthe roll of printed web product. Then, at operation 1206, the methodcomprises determining a waste tolerance for the roll of printed webproduct. At operation 1208, the method comprises comparing thedetermined waste amount with the determined waste tolerance thresholdand, then, at operation 1210, determining whether or not to use the reeleditor to edit the roll of printed web product based on the comparison.Further, at operation 1212, an indication or instruction is providedaccordingly.

FIGS. 17-18 illustrate flowcharts of a system, method, and computerprogram product according to various example embodiments describedherein. It will be understood that each block of the flowcharts, andcombinations of blocks in the flowcharts, may be implemented by variousmeans, such as hardware and/or a computer program product comprising oneor more computer-readable mediums having computer readable programinstructions stored thereon. For example, one or more of the proceduresdescribed herein may be embodied by computer program instructions of acomputer program product. In this regard, the computer programproduct(s) which embody the procedures described herein may be storedby, for example, the memory and executed by, for example, the controller90. As will be appreciated, any such computer program product may beloaded onto a computer or other programmable apparatus to produce amachine, such that the computer program product including theinstructions which execute on the computer or other programmableapparatus creates means for implementing the functions specified in theflowchart block(s). Further, the computer program product may compriseone or more non-transitory computer-readable mediums on which thecomputer program instructions may be stored such that the one or morecomputer-readable memories can direct a computer or other programmabledevice to cause a series of operations to be performed on the computeror other programmable apparatus to produce a computer-implementedprocess such that the instructions which execute on the computer orother programmable apparatus implement the functions specified in theflowchart block(s).

CONCLUSION

Many modifications and other embodiments of the inventions set forthherein may come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the embodiments of the invention are not to belimited to the specific embodiments disclosed and that modifications andother embodiments are intended to be included within the scope of theinvention. Moreover, although the foregoing descriptions and theassociated drawings describe example embodiments in the context ofcertain example combinations of elements and/or functions, it should beappreciated that different combinations of elements and/or functions maybe provided by alternative embodiments without departing from the scopeof the invention. In this regard, for example, different combinations ofelements and/or functions than those explicitly described above are alsocontemplated within the scope of the invention. Although specific termsare employed herein, they are used in a generic and descriptive senseonly and not for purposes of limitation.

1. A system for editing a roll of printed web product, the systemcomprising: a first winding station comprising a winding device that isconfigured to wind and unwind the roll of printed web product, whereinthe first winding station is configured to receive the roll of printedweb product; a cutting station configured to enable one or more portionsof the roll of printed web product to be removed; a second windingstation that is configured to receive a tail end of the roll of printedweb product and enable winding and unwinding of the roll of printed webproduct; a reel editor module configured to: receive a control planassociated with the roll of printed web product, wherein each roll ofprinted web product is associated with a roll-specific control plan,wherein the control plan comprises roll data that includes datacorresponding to one or more printed orders on the roll of printed webproduct, wherein the roll data comprises waste data that includes one ormore locations of waste sections on the roll of printed web product,wherein each of the waste sections corresponds to at least one of wasteon the roll of printed web product or unsatisfactory images that areprinted on the roll of printed web product; control the first windingdevice to unwind the roll of printed web product to position a locationof a waste section of the roll of printed web product at the cuttingstation for removal of the waste section to form an edited roll ofprinted web product; control at least one of the first winding device ofthe first winding station or a second winding device of the secondwinding station to wind the edited roll of printed web product afterremoval of the waste section; and update the control plan associatedwith the roll of printed web product by updating the roll data based onthe removed waste sections to form an updated control plan associatedwith the edited roll of printed web product.
 2. The system of claim 1,wherein the reel editor module is further configured to control at leastone of the first winding device or the second winding device to unwindthe edited roll of printed web product at the second winding station andrewind the edited roll of printed web product at the first windingstation to form an updated roll of printed web product that is rewoundwith a leading tail end on the outside circumference of the roll ofprinted web product.
 3. The system of claim 1, wherein the reel editormodule is configured to pull the control plan from a vision systemmodule.
 4. The system of claim 1, wherein the reel editor module isconfigured to provide the updated control plan to a corrugator controlmodule for corrugation of the edited roll of printed web product.
 5. Thesystem of claim 1, wherein the reel editor module is configured to causeone or more labels to be printed, wherein the one or more labels includeidentification of the edited roll of printed web product.
 6. The systemof claim 1, wherein the roll data comprises a length of printed webproduct associated with an order section on the roll of printed webproduct, wherein each order section comprises at least one structureoutline and at least one corresponding printed image within the at leastone structure outline, and wherein the reel editor module is configuredto update the control plan by updating, in an instance in which aportion of an order section was removed, the roll data with an updatedlength of printed web product associated with the order section.
 7. Thesystem of claim 1, wherein the roll data comprises a number of boxoutlines associated with an order section on the roll of printed webproduct, wherein each order section comprises at least one structureoutline and at least one corresponding printed image within the at leastone structure outline, and wherein the reel editor module is configuredto update the control plan by updating, in an instance in which aportion of an order section was removed, the roll data with an updatedremaining number of structure outlines associated with the order sectionon the edited roll of printed web product.
 8. The system of claim 1,wherein the roll data comprises an overall length of printed web producton the roll of printed web product, and wherein the reel editor moduleis configured to update the control plan by updating the roll data withan updated overall length of printed web product based on an overalllength of web product that was removed.
 9. The system of claim 1,wherein the cutting station comprises a slitting section configured toenable slitting the roll of printed web product into one or morenarrower rolls.
 10. The system of claim 9, wherein the roll of printedweb product is slit into one or more narrower rolls based on one or morelanes that are indicated in the control plan.
 11. The system of claim 9,wherein the reel editor module is configured to update the control planby generating a control plan for each of the one or more narrower rolls.12. The system of claim 1 further comprising one or more detectors fordetecting one or more markers on the roll of printed web product, andwherein the reel editor module is configured to determine a currentposition of the roll of printed web product based on the detected one ormore markers.
 13. The system of claim 12, wherein the one or moremarkers are color markers.
 14. A system for editing a roll of printedweb product, the system comprising: a controller; and a memory includingcomputer program product stored thereon, wherein the computer programproduct is configured, when executed by the controller, to: receive acontrol plan associated with the roll of printed web product, whereineach roll of printed web product is associated with a roll-specificcontrol plan, wherein the control plan comprises roll data that includesdata corresponding to one or more printed orders on the roll of printedweb product, wherein the roll data comprises waste data that includesone or more locations of waste sections on the roll of printed webproduct, wherein each of the waste sections corresponds to at least oneof waste on the roll of printed web product or unsatisfactory imagesthat are printed on the roll of printed web product; control a firstwinding device to unwind the roll of printed web product to position alocation of a waste section of the roll of printed web product at thecutting station for removal of the waste section to form an edited rollof printed web product; control at least one of the first winding deviceor a second winding device to wind the edited roll of printed webproduct after removal of the waste section; and update, in the memory,the control plan associated with the roll of printed web product byupdating the roll data based on the removed waste sections to form anupdated control plan associated with the edited roll of printed webproduct.
 15. The system of claim 14, wherein the computer programproduct is further configured, when executed by the controller, tocontrol at least one of the first winding device or the second windingdevice to unwind the edited roll of printed web product at a firstwinding station and rewind the edited roll of printed web product at asecond winding station to form an updated roll of printed web productthat is rewound with a leading tail end on the outside circumference ofthe roll of printed web product.
 16. The system of claim 14, wherein theroll data comprises a length of printed web product associated with anorder section on the roll of printed web product, wherein each ordersection comprises at least one structure outline and at least onecorresponding printed image within the at least one structure outline,and wherein the computer program product is further configured, whenexecuted by the controller, to update the control plan by updating, inan instance in which a portion of an order section was removed, the rolldata with an updated length of printed web product associated with theorder section.
 17. The system of claim 14, wherein the roll datacomprises a number of box outlines associated with an order section onthe roll of printed web product, wherein each order section comprises atleast one structure outline and at least one corresponding printed imagewithin the at least one structure outline, and wherein the computerprogram product is further configured, when executed by the controller,to update the control plan by updating, in an instance in which aportion of an order section was removed, the roll data with an updatedremaining number of structure outlines associated with the order sectionon the edited roll of printed web product.
 18. The system of claim 14,wherein, in an instance in which the roll of printed web product is slitinto one or more narrower rolls, the computer program product is furtherconfigured, when executed by the controller, to update the control planby generating a control plan for each of the one or more narrower rolls.19. A method for editing a roll of printed web product, the methodcomprising: receiving a control plan associated with the roll of printedweb product, wherein each roll of printed web product is associated witha roll-specific control plan, wherein the control plan comprises rolldata that includes data corresponding to one or more printed orders onthe roll of printed web product, wherein the roll data comprises wastedata that includes one or more locations of waste sections on the rollof printed web product, wherein each of the waste sections correspondsto at least one of waste on the roll of printed web product orunsatisfactory images that are printed on the roll of printed webproduct; controlling a first winding device to unwind the roll ofprinted web product to position a location of a waste section of theroll of printed web product at the cutting station for removal of thewaste section to form an edited roll of printed web product; controllingat least one of the first winding device or a second winding device towind the edited roll of printed web product after removal of the wastesection; and updating, in the memory, the control plan associated withthe roll of printed web product by updating the roll data based on theremoved waste sections to form an updated control plan associated withthe edited roll of printed web product.
 20. The method of claim 19further comprising controlling at least one of the first winding deviceor the second winding device to unwind the edited roll of printed webproduct at a first winding station and rewind the edited roll of printedweb product at a second winding station to form an updated roll ofprinted web product that is rewound with a leading tail end on theoutside circumference of the roll of printed web product. 21.-40.(canceled)